Quality production of flush doors
Read to find some of the most valuable tips for manufacturing high-quality flush doors.
We have received numerous letters from readers urging us to write regarding European Technology to manufacture high quality Flush doors, so we have specially surveyed the Italian door industry. We present this article based on our survey, with a few but most valuable tips to produce export quality doors.
A flush door is a product manufactured on a very large scale in India. Nowadays imported flush doors are flooding the market. We feel that this is right time for Indian manufacturer to know regarding advanced European Technology for production of flush doors.
Flush doors can be categorised as follows
-Solid wood flush doors. - Honey comb flush doors.
- Honeycomb flush doors with glass panels/ Wooden grills.
-Honeycomb flush doors with serigraphy papers
-Doors with embossed door skin.
COMPONENTS OF A FLUSH DOOR:
A flush door is made of following components:
1.Wooden outer/ inner frame.
Precisely dried timber of required species are used for outer & inner frames. The thickness of doors range from 30 mm. To 45 mm.The sawn timber is passed through four side planner moulder to size it accurately to required dimensions. A breathing groove is made from inside . This timber is then cut to required length & width. The wood has many defects still, these can be cut off by radial saw and then can be finger jointed by using a spindle moulder.
The outer frame is steppled together. Inner frame is also made if needed to accommodate glass panel, wooden or metal grill etc. A marking of this position of inner frame is done on the face MDF , so that the groove can be cut accurately to remove the face from this area. This is done by a jig mounted on Router or by a program on a CNC Router.
Solid wooden pieces of required sizes are placed accurately to accommodate door lock, eye hole etc; marking for these is done on the face to give the operator an idea of exact program.
The thickness of the wooden frame is selected
according to the thickness of honeycomb paper, or the thickness of solid wood filler strips. If the thickness is not selected properly the surface of the door shall tend to be uneven & wavy. Such surface shall look very objectionable after painting.
2.Top & bottom face - MDF / plywood / skin
Usually 3- 4 mm. MDF or plywood is used as a face material. The size can vary according to requirement.
Embossed door skins are also readily available in market. These door skins are upgraded with PVC / paper or transfer foil. Such upgrading eliminates the need for painting of the surface
Choice of filler material is made according to placing of door.
A)Main entrance flush doors:
All the main entrance flush doors have a solidwood core. To fill the door, uniformly thick wooden pieces of dried timber are used. This core makes the door very strong but also results in heavy doors.
B)Internal partition doors:
For all internal partition doors, honeycomb paper is used as an ideal filler material.Use of honeycomb paper makes the door very light in weight & results in a smooth surface finish.