Described are methods of making a paint roller using thermoplastic strip material, adhesive and a composite cover material. The materials can be assembled in a continuous manufacturing process by helically winding a strip comprising polypropylene around a mandrel so as to form a helically wound strip, advancing the wound strip along the mandrel, applying a molten layer of adhesive comprising polypropylene onto the outer surface of the wound strip, wrapping a strip of composite cover material about the wound strip and over the layer of adhesive, and allowing the adhesive to cool, thereby laminating the composite cover material with the outer surface of the wound strip.