METHODS OF MAKING PAPER PRODUCTS USING A PATTERNED CYLINDER

A method of making a fibrous sheet, the method comprising: (a) forming a nascent web from an aqueous solution of papermaking fibers; (b) applying the nascent web to an outer surface of a steam filled drum and dewatering the nascent web by moving the nascent web on the outer surface of the steam filled drum to form a dewatered web having a consistency from about thirty percent solids to about sixty percent solids; (c) transferring the dewatered web from the outer surface of the steam filled drum to a patterned surface of a patterned cylinder in a molding zone, the molding zone being a nip defined between the outer surface of the steam filled drum and the patterned surface of the patterned cylinder, the patterned surface (i) being formed on the exterior of the patterned cylinder and (ii) having at least one of a plurality of recesses and a plurality of protuberances, such that papermaking fibers of the dewatered web are (i) redistributed on the patterned surface and (ii) shaped by at least one of the plurality of recesses and the plurality of protuberances of the patterned surface in the molding zone to form a molded paper web; (d) transferring the molded paper web from the patterned surface of the patterned cylinder to a pickup surface; and (e) drying the molded paper web in a drying section to form a fibrous sheet.