How Are Composite Doors Made?


Residential doors have gone through a lot of changes over the years, including the technology and the materials they are made from. 

Whereas previously wood was the go-to material for doors, uPVC quickly took over, offering higher durability and energy-efficiency.

Today, the composite door is one of the most popular door types. 

Unlike other single-material doors, composite doors are made from various materials, specifically chosen for their individual qualities, resulting in a more robust product. 

Thanks to their superior strength, composite doors offer greater security, insulation, and durability, unmatched by its counterparts. 

But how are composite doors made exactly? 

Let’s take a closer look. 

What are composite doors made from? 

Composite doors are the result of combining various materials including a solid timber core, glass-reinforced plastic and uPVC. 

Composite doors composition may vary, however, typically it is made from:

  • a solid timber core, or insulating polyurethane foam
  • an inner frame made from hardwood 
  • a subframe
  • a glass-reinforced plastic or a uPVC ‘skin’

Making a composite door

The construction process of a composite door may vary depending on the style or design you choose. But generally composite doors are made in this process:

  1. The first thing that is built is the frame of the door, cut to specific measurements. The frame of the door will typically be made from reinforced structural members. 
  2. The hardwood or uPVC inner frame is placed to fit the outer frame. 
  3. The next thing to be added is the locks, hinges, and latches. 
  4. Generally made from durable uPVC or glass-reinforced plastic, the front and back faces of the door will be attached. 
  5. At this point in the construction process, expanding polyurethane foam would be injected between the faces. To penetrate the door structure, it will be injected at high pressure. 
  6. The finishing touches of the door will then be added. This includes the cutting and fitting of any windows. 
  7. The door is now finished and ready to be delivered. 

Installing a composite door 

Choosing to install a composite door rather than a traditional timber or uPVC door means that your home will be more secure, better insulated and your door will be more durable. By fusing different materials together, the flaws of single-material doors can be essentially ‘designed out’. 

Despite the benefits of composite doors, just like any other type of door, it is important to choose a product from a trusted installer. 

At Classic PVC, we always aim to deliver a first-class service, supplying the finest products. We put quality first, so you can be confident that a door from Classic PVC is one that is built to last. 

If you’re looking to install a new or replacement composite door, don’t hesitate to get in touch or request a free no-obligation quote today. 

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