INTERIOR DOOR OPTIONS

Solid Core Doors

Solid core doors are constructed using a denser core material, such as particleboard, fibreboard, or solid wood, which is sandwiched between two or more layers of plywood or MDF. The manufacturing process for solid core doors is more complex than for hollow core doors, and typically involves several steps.

The first step in manufacturing a solid core door is to select and prepare the core material. The core material is typically made of a composite of wood fibres, such as particleboard or MDF, which are glued and pressed together under high pressure to create a dense, sturdy core. The core material may also be made of solid wood, which is cut and planed to size.

Once the core material has been prepared, it is coated with adhesive and sandwiched between two or more layers of plywood or MDF skins. The skins are then pressed together under high pressure to create a strong bond. The door is then trimmed to size and sanded to create a smooth surface.

After the door has been assembled, it may be finished with a layer of veneer or paint. Solid core doors can also be made with a pre-finished surface that requires no additional painting or staining.

Solid core doors offer several advantages over hollow core doors, including increased durability, improved noise reduction, and better insulation. They are also more resistant to warping, cracking, and other types of damage. However, they are typically more expensive and heavier than hollow core doors, and may require more effort to install.

Hollow Core Doors

Hollow core doors are a type of interior door that is constructed using a lightweight core material, typically made of cardboard or honeycomb-shaped cells, sandwiched between two thin sheets of plywood or medium-density fibreboard (MDF).

The manufacturing process for hollow core doors involves several steps. Firstly, the core material is cut to size and shaped into a honeycomb pattern or a series of channels. The plywood or MDF skins are then attached to the core material using adhesive, and the entire assembly is pressed together under high pressure to create a strong and stable bond.

Once the door has been assembled, it is trimmed to size and sanded to create a smooth surface. The door is then ready for finishing, which may involve painting, staining, or applying a clear coat.

Hollow core doors are a popular choice for interior doors because they are lightweight, inexpensive, and easy to install. However, they are not as durable or soundproof as solid core doors, and they may not be suitable for use in areas where noise reduction or high levels of security are a priority.

Polycore doors

Polycore doors are a type of interior or exterior door that are constructed using a unique, patented manufacturing process. These doors feature a solid composite core made from recycled materials, such as cardboard, paper, and sawdust, which is sandwiched between two or more layers of high-density fibreboard (HDF) skins.

The manufacturing process for polycore doors involves several steps. Firstly, the recycled materials are processed and formed into a solid core, which is then coated with a layer of waterproof adhesive. The HDF skins are then laminated onto the core using heat and pressure, creating a strong and durable bond.

One of the key benefits of polycore doors is their resistance to moisture and humidity. The solid composite core and HDF skins are impervious to water and moisture, making these doors ideal for use in areas with high levels of humidity or moisture, such as bathrooms, laundry rooms, and basements.

Polycore doors are also environmentally friendly, as they are made from recycled materials and are fully recyclable at the end of their lifespan. They are available in a range of styles and finishes, and can be customised to fit a wide variety of applications and design preferences.

Polycore doors are a durable, moisture-resistant, and eco-friendly option for interior and exterior door applications.