A thin-walled fuser roll core cylinder assembly permitting fast warm-up times and improved energy efficiency wherein cracking of the thin walls due to cyclic compression is prevented by strengthening the thin walls proximate to the end region where the core cylinder is engaged by the drive gear. Use of such a thin-walled fuser roll in an imaging system and a process of fusing toner onto a copy substrate using the thin-walled fuser core.

 
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