How Are Composite Doors Made?

Published on: 26th July 2023


The world of house exteriors has never seen anything like composite doors, which provide the ideal balance of elegance, strength, and security. Composite doors have emerged as the top option for homeowners looking for an improved substitute for conventional wooden or uPVC doors, whether you’re remodelling your front entry or replacing an outdated door. Have you ever thought about what makes composite doors so unique, though? Let’s examine the production of these astonishing doors to comprehend the engineering and handiwork that went into making them.

The Composite Door Manufacturing Process

Step 1: Designing the Door

The process of making a composite door starts with careful planning and design. Professional designers create door designs that take into account various architectural types and consumer preferences using cutting-edge technologies. Colour, finish and optional features like glazing and ornamental panels are all options made during the design process.

Step 2: Preparing the Materials

Gathering the necessary materials kicks off the production process when the design is complete. The chosen skin material (GRP or uPVC) and the core material (usually high-density polyurethane foam) are ready for assembly.

Step 3: Creating the Door Skin

Precise manufacturing methods are used in the fabrication of the door skin. The glass-reinforced plastic is moulded into the necessary shape for GRP composite doors using a specialised mould. To guarantee smooth finishing and avoid flaws in the finished product, the mould is covered with gel.

Step 4: Assembling the Core

The insulating and strength-giving core material is precisely cut and formed to fit inside the door frame. The foam core is made to meet the shape and measurements of the door, guaranteeing a tight fit and top performance.

Step 5: Bonding Process

Industrial-grade adhesives are used to join the door skin and core material during this crucial step. The bonding procedure makes sure that the two parts join together to form a sturdy structure that can resist time and a variety of weather conditions.

Step 6: Finishing Touches

Although the composite door is now entirely put together, it is not quite ready. Expert craftspeople apply precise finishing touches to make sure every detail is correct. Sanding, painting, staining, and any ornamental accents that may improve the door’s look are all part of this stage.

Composite Door Materials

Core Material

The core material serves as the structurally sound and insulating centre of a composite door. A common choice for the core material is high-density polyurethane foam because of its remarkable thermal efficiency and lightweight attributes. This foam core improves the door’s ability to conserve energy while also strengthening the construction as a whole.

Skin Material

The skin, or outside layer, of a composite door determines the door’s look and longevity in a significant way. Both uPVC and Glass-Reinforced Plastic (GRP), which both provide great weather resistance and need little maintenance, are frequently used to make the skin. The precise design and performance qualities sought for the door will influence the skin material choice.

GRP Composite Doors

GRP, or glass-reinforced plastic, is a durable and adaptable material that is often used in the creation of composite doors. GRP is a composite material created from a matrix of polymer resin and fine glass fibers. GRP’s high strength-to-weight ratio and resilience to a variety of environmental variables are both a result of its distinctive composition.

GRP composite doors are a great option for homeowners looking for durability and design because of their many advantages. GRP composite doors have a number of benefits that set them apart from the competition, including improved security measures and superior thermal insulation.


Composite doors are a top option for homeowners looking for an exceptional entryway solution since they are the ideal combination of design, strength, and sustainability. Each composite door is expertly created during the painstaking production process, providing unrivalled durability and aesthetic appeal. Composite doors continue to revolutionise home exteriors with a variety of styles and customisation possibilities, making a positive impression on visitors and bystanders alike.