Dimensionally stable sheet handling shaft assembly and method of making same

A shaft assembly having stable dimensions for forming a precise sheet drive nip in a sheet handling machine, the shaft assembly comprising:

• (a) a tube member having a tube wall defining an outer surface, an interior, and at least a perforation through said tube wall into said interior for moldable material flow;
• (b) a core member formed within said interior, said core member consisting essentially of a first molded material;
• (c) a sheet drive-effecting member formed integrally with said core member and on said outer surface of said tube member, said sheet drive-effecting member having desired external dimensions and consisting essentially of said first molded material;
• and
• (d) an elastomeric alloy thermoplastic elastomer (TPE) material layer formed over said desired external dimensions of said sheet drive-effecting member for forming the precise sheet drive nip, said elastomeric alloy TPE material consisting essentially of a thermoplastic vulcanizate (TPV) including a plastic material phase and a vulcanized rubber phase.