Composite doors are a popular choice for homeowners due to their durability, security, and aesthetic appeal. Unlike traditional wooden doors, composite doors are made from a combination of materials, including wood, uPVC, foam, and glass reinforced plastic (GRP). In this blog post, we will take a closer look at the manufacturing process of composite doors.

Step 1: Design and Material Selection

“The first step in making a composite door is to design the door and select the materials” Says Sam an expert installer from Value Doors. The design is typically done using CAD software, and the materials are chosen based on their properties and suitability for the intended purpose of the door.

Step 2: Cutting and Preparation

Once the design and materials are selected, the next step is to cut and prepare the materials. The uPVC frames are cut to size and the foam core is shaped to fit the door’s dimensions. The GRP skin is also cut to size and shape, and any necessary glazing apertures are cut out.

Step 3: Bonding

The bonding process is crucial to the strength and durability of the composite door. The uPVC frame is bonded to the foam core using a high-strength adhesive. The foam core is then bonded to the GRP skin using a similar adhesive. The bonding process ensures that the door is strong and durable, and also provides insulation against heat loss.

Step 4: Finishing

Once the bonding is complete, the composite door is ready for finishing. The door is sanded to a smooth finish and any imperfections are filled in. The door is then ready for painting or staining, depending on the customer’s preference. The final finish not only enhances the door’s appearance but also provides protection against the elements.

Step 5: Quality Control

Before the door is shipped to the customer, it undergoes a rigorous quality control process. The door is inspected for any defects, and the measurements are checked to ensure they are within tolerance. The hardware is installed, and the door is checked for proper operation, security, and weatherproofing.

In conclusion, composite doors are made using a combination of materials and a multi-step manufacturing process. The result is a strong, durable, and aesthetically pleasing door that can provide security and insulation for many years.