How Composite Doors Are Made

The process starts with two sheets of fibreglass matting.

The sheets are carefully placed on the aluminium door leaf mould.

The sheets are combined with resin and heated under pressure to create the outer and inner door leaves.

The newly pressed sheets are then inspected and the grain on the mould is verified.

The double rebated inner frame is machined to size and the corners are welded.

The inside pressed sheet is married to the welded inner door frame manufactured to the precise customer door measurements.

The frame is then pressed to ensure the frame and leaves bond fully.

The inner void is filled with insulating foam before undergoing a curing process.

The oversized leaves are cured without pressure before undergoing the next step.

All apertures for windows, letterboxes, handles or locks are precisely machined into the panel at this stage. The double rebate is also machined.

If a premium colour has been selected the precisely sized panels are painted to the customer's speciifcation. Particular care is taken to ensure the deep grain is enhanced.

The painted panels undergo a full inspection before the paint fully cures to ensure full coverage and grain enhancement is achieved.

Whilst the panels are curing, any decorative glass panels required are precisely created in the Glass Studio.

If sandblasted opaquing is required for privacy or to incorporate house names or numbers, individual glass panes are created.

The triple glazed sealed units are created, incorporating decorative glass.

The sealed units, hinges and door furniture are added to the coloured panel to form the finished door.

The door is hung, tested and inspected precisely to exacting standards.

The finished door is wrapped for protection before leaving the factory to installation depots throughout the country.