Methods and apparatus for forming cylindrical photosensitive elements

An apparatus for forming a seamless cylindrical photosensitive element on a flexible sleeve, comprising:

• a mandrel having a longitudinal axis, a first end and a second end, the mandrel for supporting the sleeve in a substantially cylindrical shape such that the sleeve is rotatable with or about the mandrel;
• a mandrel support assembly for supporting at least the first end of the mandrel;
• a calendering assembly for metering a substantially cylindrical molten stream, or a molten or solid sheet, of photopolymerizable material on the sleeve to have a substantially constant thickness, the calendering assembly comprising at least one calender roll positioned to contact the photopolymerizable material on the sleeve;
• a drive system for rotating the calender roll while simultaneously moving the sleeve axially along the longitudinal axis of the mandrel, thereby moving the sleeve around and along the longitudinal axis of the mandrel in a helical fashion so that the calendering assembly polishes an outer circumferential surface of the element to a seamless uniform state without sanding, grinding or additional polishing apparatus;
• and
• at least a heating element for heating the photopolymerizable material while the element is being formed.