How to organize the production of doors from MDF. Manufacture of interior doors. Wooden with veneer

The segment of the market for the production of interior doors will always be in demand. Good, solid interior doors will always find their buyer and give a good profit.

So, what do you need to start a business for the production of oak and other wooden interior doors from timber?

Door types

Before purchasing equipment and renting premises for the production of wooden interior doors, it is necessary to determine the range of products manufactured in the future.

Wooden doors are of the following types:

From a wooden massif of various species. Such interior doors are produced from wooden blocks of high-quality expensive wood species, which are spliced together. The resulting solid wood is sanded, calibrated and varnished in the desired shade. Mosaic splicing and toning is possible even in the bars. In such cases, the resulting array is covered with a colorless varnish. For VIP doors, whole pictures are laid out.
Veneered (veneered) doors. The production of such interior doors consists in veneering doors made of boards, solid wood or made using the technology of a wooden frame, which is filled with honeycomb cardboard, with precious wood veneer. They are in no way inferior in appearance to natural solid wood doors, but they are less durable, more capricious in operation and, if not properly maintained, will require an early restoration. The owner of the workshop for the production of wooden interior doors, when producing products of this type and providing a guarantee, must keep the veneer that matches the sold interior doors in order to eliminate deficiencies during the warranty period;
Laminated. It is an economy class door, in which a laminated film of the texture and color chosen by the customer is applied to the wooden frame. The price of such doors depends on the method of applying such a coating and its composition.

In this article, we consider the technological scheme for launching a workshop for the production of interior doors from sawn oak.

Product range

door frames;
platbands;
interior doors;
products per linear meter - door array, etc.

Sales channels

The organization does not plan to carry out independent installation of its products, finished products will be sold through such distribution channels as: 1) wholesale of interior doors to construction organizations that renovate offices, apartments, etc.; 2) retail outlets selling building materials, windows and doors; 3) construction hypermarkets and large specialized stores.

Raw materials for production

Planned raw materials for the production of interior doors:

Timber. The cost of a cubic meter of sawlogs, for example, oak, will be approximately equal to 5000-7000 rubles per cubic meter.
Glue for end splicing of beams. Such an adhesive is Kleiberit 303.2. Its consumption is 160 grams per square meter. The price for a container weighing 1 ton will be approximately 110 thousand rubles.

Equipment for the production of

You will need the following equipment for the production of interior doors:

band sawmill. You can, of course, buy ready-made boards, beams, but then the doors will come out very expensive. Price from 110-130 thousand rubles.
Drying chamber. Necessary for faster drying of wood. In general, this process will need to be approached with all seriousness, because. if you do not dry the wood, then the doors will warp, and this will lead to negative reviews about your products and general dissatisfaction with your customers. Who will need such products, in which cracks are then formed due to continued drying? Nobody.
Tenoning machine. About 200 thousand rubles. Designed for precise trimming, cutting mini-studs on workpieces for their subsequent splicing. Those. he makes castles.
End splicing press. From 220 thousand rubles. As a matter of fact, this press is just engaged in splicing through the ends and cuts that the previous machine made.
Pneumatic press for wooden board splicing. Thanks to him, the entire shield is formed from the previous parts received. From 200 thousand rubles.
Panel saws. 220 thousand rubles Designed for cutting lumber. They produce longitudinal, transverse, as well as sawing lumber at an angle.
Milling and copying machine. About 150 thousand rubles. Produces exact copies of wooden parts, which saves a lot of time in the production of the same type of parts.

The total cost of purchasing equipment (without a dryer) for the production of interior doors will be about 1.5 million rubles. Dryers are not sold ready-made, but are made to order. Therefore, we cannot indicate their price here, because prices vary greatly.

Production technology

The entire manufacturing technology of interior doors consists of the following production stages:

Sawing of raw materials;
Drying of blanks;
Dissolution of unedged boards;
Cutting spikes and splicing blanks;
Cut and calibration of defective places;
Glue is applied and the blanks are spliced into a wooden shield;
Calibration of canvas dimensions;
Coating grinding;
Varnishing and applying a special solution;
Final drying of the finished product.

Interior doors are a necessary part of residential, industrial and office premises. When choosing door panels and additional elements, you need to know how and according to what rules they are made, as well as to understand the advantages and disadvantages of the materials used in the production of doors. Modern manufacturers use high-tech equipment that allows them to produce a large number of high-quality products with various types of coating and modern design.

Manufacturing technology of interior doors

Doors serve to separate the various functional parts of the room and provide sound insulation, protection from extraneous odors and excessive moisture. Methods for the manufacture of door panels and additional elements depend on the materials used in the production. The most popular doors are made of solid wood or prefabricated on a wooden frame. Glass inserts make the canvas partially transparent to light and visually expand the space of rooms or corridors.

The most complex and multi-link technological process occurs in the manufacture of doors using wooden elements. The fact is that timber that has not gone through the full cycle of pre-drying and processing is subject to warping and cracking. To avoid losses in the quality of the final product, it is necessary to pay great attention to the preliminary preparation of wood using certain technological methods. The manufacturing process of interior doors includes the following steps:

Timber (round timber) of pine species is sawn into blanks using band saws with automatic feeding of logs.
Logs are sawn into blanks of the required thickness.
The blanks are treated with high temperature and steam in drying chambers to avoid uneven drying and warping of the wood. At the end of the drying process, a mandatory moisture control is carried out.
Drying of lumber is carried out under the influence of steam and high temperature.
Dried blanks are cut into bars of technological section and defective fragments (chips, knots, cracked and rotten areas) are removed from them, which can affect the quality of the door frame and leaf.
Defective areas are cut out of a blank cut into a beam
Then, the blanks are spliced with the help of spikes, glue and a vertical press into a shield, from which, after drying and trimming, a door leaf is obtained.
With the help of a vertical press, a panel blank of the door leaf is obtained
After sanding, the canvas is covered with three-layer veneer or MDF panels with one layer of veneer and placed in a gluing press.
At the next stage, figured decorating elements, panels or openings for glazing are cut out with a milling and engraving machine, and after assembly, the door leafs are covered with three layers of varnish with intermediate and final polishing.
Panel elements or glazing are mounted during final assembly
After the final drying, the products are packed, if necessary, supplied with fittings and sent to the consumer.

The technological sequence of manufacturing doors may be different and it depends on the material, equipment and design of the product. For example, expensive solid wood doors do not typically use veneer and are manufactured using complex CNC machines, while budget doors often use corrugated board inserts and cheap laminating film.

It is important to note that in the factory, fittings are usually not installed on a door with a symmetrical decor, since during installation at the consumer's, the product can open both to the left and to the right, respectively, the hinges and handles are installed by installers on site.

Video: making solid wood doors

Rules and norms for the production of interior doors

Door blocks are manufactured on equipment that is located on large production areas. These premises are subject to certain requirements, as to industrial facilities, which include timber warehouses, dryers, a processing shop, a paint shop and a warehouse for finished products. Each production site is equipped according to the rules and regulations, in accordance with the technical conditions for a specific task. The main requirements for production facilities for the manufacture of doors are the following criteria:

availability of free access roads;
buildings must be provided with a stable temperature, humidity, natural and artificial lighting;
power supply, heating, ventilation, water supply and sewerage should be equipped;
the premises must be equipped with fire alarms, fire extinguishers and emergency exits;
it is necessary to ensure safe working conditions at workplaces;
paintwork areas should be isolated from the rest of the premises and provided with forced ventilation.

Personnel are required to undergo professional training and training in labor protection, fire and electrical safety standards, as well as undergo unscheduled, repeated and initial briefings at the workplace.

The production room must be equipped in accordance with the standards

The main norm for the production process is technological documentation, which is based on the Technical conditions for the production of TU 5361-001-58037723-2015 "INTERIOR DOORS, PARTITIONS AND MOLDINGS TO THEM". This document sets out the requirements for the design of interior doors, the quality of the material and the coating of the front surface, as well as environmental requirements. The regulations specify the procedure for acceptance of finished products, certification and installation of a warranty period of operation.

For the buyer, it is important to have a certificate, a warranty period and the compliance of the door, frame and additional elements with the requirements of technical specifications, since this confirms the quality of the product and allows you to count on a long service life.

Current GOSTs for the production of interior doors

The technical characteristics of the doors are determined by the standards that set the general technical conditions or methods for determining the physical parameters and dimensions of the finished product. Many manufacturers create products according to non-standard sizes, but with strict observance of quality requirements. The consumer may be interested in the list of regulatory standards that manufacturers of interior doors work on, namely:

General requirements for wooden doors with a list of regulatory documents are established by GOST 6629–88, and requirements for wood products are set out in GOST 475–78.
Design options for interior doors, their types and sizes are specified in GOST 24698–81.
Requirements for extensions, fasteners and hinges are assigned by GOST 538–88.
Methods for determining sound insulation, heat transfer resistance and air permeability are regulated by GOST 26602.
The determination of the flatness of the door leaf is carried out according to the standard ST SEV 4181–83.
The reliability test methodology is set out in ST SEV 3285–81.
Impact load resistance is produced according to the method specified in ST SEV 4180-83.

Accompanying documents for finished products must contain a symbol for door panels, for example, U05195 VERSAL pat. 1014 dec/or door leaf D3 91x 230 L, which means the following door parameters:

article - U05195;
the trade name of a particular collection is VERSAL;
type of finish/color − pat. 1014 dec/oro;
product name - canvas;
product model - D3;
width and height of the canvas - 91x230;
type of opening, left − L.

Before ordering doors, it is necessary to carefully measure the doorways in order to select the required size of the frame, leaf and the required number of additional elements. For interior doors, there are standard dimensions of openings with the corresponding designation according to SNiP, and this approach makes it easier to choose a door frame according to the table.

Table: the ratio of the size of the opening to the size of the door leaf

Existing regulatory documents guarantee a high level of product quality, standardization in size and compliance with environmental requirements, in addition, the consumer can determine the compliance of the product properties declared by the manufacturer with the quality and price level.

Material for the manufacture of interior doors

In the production of interior doors and partitions, modern materials are used that are environmentally friendly, durable, lightweight and have a long service life. These include metal-plastic and glass doors, the frame for which is an aluminum profile, and the filler is plastic panels or tempered triplex glass with a matte finish. But traditional doors with a wooden frame and inserts made of glass, MDF panels and paneled elements occupy a major niche in the market. In the manufacture of such products, the following materials are used:

Defect-free pine lumber with a moisture content of not more than 8%, spliced into a tenon using glue pressing.
High density chipboard.
Natural veneer from various types of wood with a thickness of 0.6 mm.
Laminating film imitating fine wood.
Laminating film gives the doors the texture of natural wood
MDF panels of various thicknesses are used for cladding door panels and creating paneled elements.
Frosted, triplex or tempered glass is used for light-scattering and decorative inserts in the door leaf.
Corrugated cardboard is used in budget options as soundproof inserts in the canvas between the frame bars.
Corrugated cardboard is used for insulation and sound insulation of inexpensive door panels.
Wax and waterproof coatings, tinting compounds and varnishes.
Glue type "Kleiberit 303.2", MERITIN ADHESIVE D3 and others, is used for industrial gluing of fragments of leaves, door frames and additional elements.

The production of inexpensive doors is based on the use of chipboard, laminating film, corrugated board and MDF, while more expensive products use solid wood with milled elements, panels and tempered glass inserts.

Six years of experience in the operation of veneered panel doors by the author of the article shows their significant reliability. But in rooms with high humidity, I would like to recommend different types of laminated doors with an additional waterproof coating. After four years of service in the bathroom on the inner veneered canvas, despite the treatment with liquid wax twice a year, whitish stains and streaks appeared from exposure to steam and condensate. There was a need for cosmetic repairs, so I had to sand the plane of the door leaf, degrease it with a solvent, cover it with a tinting compound and waterproof varnish in two layers. To a lesser extent, the same problem appeared in the laundry room, and as for the other doors, minor damage to the veneer and scratches were eliminated by gluing and treating with hard, tinted wax in various shades. After such a minor repair, the canvas, boxes and extensions acquire their original appearance and serve for more than six years. Under the conditions of suburban operation during summer residence, wooden doors covered with waterproof varnish serve more than eight years. At the same time, there is no warping and drying out in conditions of temperature changes and changes in humidity. But it should be noted that the best option for summer cottage construction are metal-plastic doors and frames that do not change their properties and retain their geometry under changeable weather conditions.

Equipment for the production of interior doors

The most costly production of interior doors, in terms of the amount of equipment required, is the manufacture of wood products. Factory production of metal-plastic and glass requires a large number of components and a small number of machines for cutting frames and processing glass sheets. Lumber processing is more saturated with machine tools, presses and other equipment. Consider the equipment that is used for the production of wooden doors:

Sawmills and band saws used for cutting round timber.
The sawmill allows you to get lumber of the required thickness from round timber
Thermal chambers with steam supply for drying lumber.
Industrial drying chambers allow you to bring the lumber to the required moisture level and avoid warping of the workpieces
Equipment for the production of veneer.
Tenoning machine for frame and door leaf.
Using a pneumatic press, the door leaf is glued
Circular saws and panel saws for sawing blanks to size.
Copy-milling machines with program control for decorating door panels.
Using milling machines, figured and paneled elements are produced
Grinding machines for intermediate and finishing processing of products.
Paint equipment.

The list of the production park can be expanded due to the use of various technological and design solutions in the production of interior doors and components, which has a positive effect on the consumer properties of the final product.

Video: production of interior doors

We examined some types of interior doors, production technology, as well as regulatory documents and requirements governing the production of this type. For the correct choice of doors, it is necessary to know the properties of the coating and the material from which they are made. High-quality equipment and adherence to production technology ensures resistance to external influences and a long service life of products. A wide range of design solutions allows you to give the living room an individual look and unique style.

Interroom door systems are an indispensable piece of furniture designed not only to delimit space, but also to isolate the room from noise, odors, etc. Naturally, high-quality structures cost a lot, and this is not surprising, because the production of interior doors of this level is a complex technological process.

Of course, the production cycle of glass, wood, aluminum doors and PVC products is fundamentally different from each other. There are differences in the process of manufacturing sliding and swing systems, standard and non-standard designs. All these points are taken into account by factories producing interior door systems.

Before purchasing equipment for the production of interior doors, factory specialists analyze the market segment, study the demand for products, and only then make an informed decision on the appropriateness of producing certain types of products.

To date, mainly manufacturers of interior doors specialize in the production of wooden structures of the following types:

Veneered.
The technology for the production of interior doors of this type provides for lining the wooden frame with a film of valuable wood species, for example, oak (film thickness, as a rule, is 1 mm). In appearance, such products cannot be distinguished from door systems made of their array. However, veneered doors have a small drawback - they are very capricious in operation and, with improper care, very soon such products will need to be restored. All these nuances are taken into account by the manufacturer. So, giving a guarantee for their products, the manufacturer must have a small supply of veneer suitable for the doors sold, in order to repair damage to veneered sliding or hinged structures if necessary.
Products from the array.
For the manufacture of such door systems, oak, pine, etc. wood can be used. Mosaic splicing of solid wood bars from different types of wood, for example, oak and beech or others, is possible. The production of solid wood doors is a complex process that requires a lot of time, as well as labor and intellectual investments.
Laminated.
The production of laminated doors includes the manufacture of a wooden frame (usually made from softwood) and covering such a base with paper or plastic film. The application of the laminated coating is carried out by pressing. Due to the huge variety of textures and colors, laminated door systems of Russian and foreign production are distinguished by a rich assortment. In most cases, the cost of these products depends on the applied coating.

Paneled door composition.

In addition, modern factories produce panel and panel products. Paneled systems are characterized by the presence of glass inserts and a panel, which is a kind of shield. The complexity of manufacturing such a design is explained by the need to use special equipment that works simultaneously with wooden and glass elements.

As for panel products, they are made of a shield, which is lined with plywood or plastic on top. Due to the absence of glass inserts, such structures are considered to be universal: door systems can be used as input or to delimit the space between rooms. The production of wooden doors of this type is not difficult, perhaps this explains such a large range of panel products.

Product manufacturing specifics

It is no secret that the production of plastic doors, wooden or glass products (whether sliding or hinged) begins with the preparation of raw materials. Therefore, each plant specializing in the production of wooden door systems has developed its own internal standards that separate all the material used in terms of quality.

The fact is that not every board can be used to produce a quality product. Therefore, this differentiation makes it possible to distinguish between high-quality wood and low-quality raw materials.

The list of equipment used by the manufacturer in the production of swing and sliding systems, standard and non-standard solutions includes the following:

sawmill;
drying chamber;
tenoning machine;
presses;
panel saw;
milling machine, etc.

Such a list may be supplemented with additional equipment depending on the type of coating or the presence of inserts and decorative ornaments. So, for example, for the production of veneered doors, one equipment will be needed, and for the production of glass inserts, another.

At the same time, it is difficult to say which production stage is the most important. They are all equal! So, for example, if the wood used for the manufacture of standard or non-standard structures is not completely dried out, the doors will look lopsided, take on a terrible look and cease to function properly.

Naturally, this state of affairs will cause dissatisfaction among buyers. Or, for example, if you make a mistake while cutting glass inserts (make the insert smaller by a couple of millimeters), the glass will constantly rattle: this is, in fact, a manufacturing defect. As a result, a dissatisfied buyer and a loss of confidence in the manufacturer's products.

Thus, even the smallest mistake in the production of sliding and swing interior systems can cost the manufacturer dearly. Therefore, factories that value their image control every technological process.

Many watched and remember Anton Vasiliev's film "You Can't Forbid to Live Beautifully", which was released in 1982 - everyone wants to live beautifully. And one of the components of such a life is the interior of our house or apartment, where interior doors that will not creak play an important role. We will talk about doors and their varieties below, and also watch the video in this article.

MDF door

A good wooden canvas costs good money, and this is not always affordable for everyone - the price of solid wood of valuable species “bites” even in such a forest-rich country as Russia. Of course, there is a way out - this is the so-called "Canadian" - a rack frame, sheathed with fiberboard, which has a rather attractive structure and is designed for painting.

But such a canvas will not create the effect of natural wood. Therefore, MDF can be called the best budget option, especially with natural veneer from valuable species.

Suddenly, like in a fairy tale ... 7 qualities

I can list at least 7 excellent qualities that doors and portals made from MDF have:

MDF sheets do not react to changes in humidity and temperature, which is very important for rooms such as or a bathroom. This means that they will not swell and, therefore, warp, and the canvas itself will always have a flat (not behaving) plane.
The construction market offers a huge range of doors both in design and color. Here, perhaps, the largest selection of all analogues existing at the moment.
Such a canvas will never delay suspensions., since the weight of the MDF interior door is too small and the metal hinges do an excellent job with it.
MDF belongs to the group of low combustible materials Therefore, such canvases are considered fireproof.
The front covering of MDF, whether natural or artificial veneer or paintwork materials, do not lose their color over time. That is, you are not afraid of the abundance of sunlight in the room, penetrating through the windows.
They are extremely easy to care for. besides, if necessary, they can also be washed with household chemicals.
And, finally, the cost of such a canvas, compared to solid wood, is quite low..

It should be noted that the restoration of MDF interior doors is possible only if the panels remain intact, since they cannot be restored.

So what is MDF

Medium Density Fibreboard (abbreviation for MDF) is medium density fibreboard. But in the Russian language there is a transliteration - MDF, which is often deciphered as a fine fraction and this is quite true.

The boards are made from small wood shavings, which are pressed under high pressure and at high temperature, which makes the material look like chipboard or chipboard.

But:

firstly, chipboard also uses large chips along with wood chips;
and, secondly, the instruction provides for the use of lignin as a binder for MDF.

But lignin is a purely natural substance (lignum in Latin means wood), which is found in the cells of vascular plants and in some types of seaweed. Therefore, the result is an environmentally friendly material, without any chemical additives.

Note. In terms of technical qualities, MDF is superior to solid wood, since such boards are lighter in weight, resistant to temperature and humidity changes, and also have higher strength.

Door designs

Designs of paintings: on the left - paneled, on the right - panel

The canvases that you see in the top photo, in fact, display all types of door structures and it is not at all necessary that they look exactly like that. Just a paneled canvas consists of several parts, where instead of panels there can be glass. And the panel sheet is the solid thickness of the entire door.

Paneled construction: 1 - standing side; 2 - baguette; 3 - panel; 4 - upper and lower sides

In the top photo you see the design, according to the principle of which panel doors are made from any materials. In the case of MDF, glass is often inserted instead of panels, and the base is either made from a solid MDF profile.

Panel board: 1 - MDF; 2 - veneer; 3- honeycomb filler; 4 - wooden frame; 5 - reinforcing elements

Panel doors are a wooden frame sheathed with MDF panels, which can be of different types. This design can serve as a bathroom or it can even be used as a front door. Such a canvas can also be solid, but it can also be glazed, which is not uncommon for MDF.

All canvases or portals made from MDF can have a slightly different surface - MDF can be veneered, laminated and painted. Of course, the most expensive will be doors covered with natural veneer, and the most moisture resistant - from laminated panels.

But the easiest repairs can be carried out for canvases for painting, since paint for MDF interior doors is sold in a huge assortment in any hardware stores.

MDF Care

As I mentioned above, MDF is not afraid of wet cleaning, but this does not mean that they can be washed with running water - there is a damp sponge for this, with which the canvas is wiped with your own hands.

In addition, you can use household chemicals, but provided that there are no abrasive substances, as this can damage the surface, leaving barely noticeable scratches, from which the background becomes, as it were, dirty or worn out. But in 99% of cases, when buying MDF doors, they are accompanied by care instructions, which specifically list all possible means and methods of cleaning.

Doors with glass fragments or glazed over the entire upper part also need care, but this does not mean at all that you can clean the entire canvas with the same tool. For glass, other compounds should be used - usually, these are all the same preparations that you use when cleaning windows and mirrors.

Conclusion

If you are thinking about how to paint MDF, then I want to remind you that this material is very similar to natural wood. Therefore, any paint and varnish compositions used for wood are appropriate here. Perhaps you have any ideas or comments, then please write about it in the comments.

The success of a business is primarily due to the popularity of its products among the general population. The most promising areas include the manufacture and installation of plastic doors and windows; production of all types of wooden and metal doors, as well as decorative overlays on them; manufacture of gates, garage doors.

How to organize such a business, how is the choice of equipment and materials, how many and what qualifications of personnel should be involved?

Based on the video in this article with the topic “Door Manufacturing Technique”, we will discuss many issues related to door production. In the article itself, a lot of useful information will be presented, which will also be useful to those who undertook to make a door with their own hands.

To organize a business, priority should be given to the range of products, which is very important for any production. Naturally, when determining it, consumer demand should be taken into account. Making room doors from solid wood and MDF is a win-win option.

With all the abundance of proposals from manufacturers involved in the production of glass and, which are also installed in apartments, they cannot compete with wooden doors. First of all, this is due to their higher cost. Moreover, if desired, a person can.

Assortment of modern carpentry

If we talk about the enterprise for the production of windows and doors, then one cannot fail to note this fact. In addition to the main assortment, the dimensions of which are focused exclusively on state standards, the workshops also manufacture doors according to the dimensions and sketches provided by the customer.

Working with natural wood, the buyer can offer a lot more. This includes carving, gilding, and colored lacquer or wax coating, inlay, as well as the manufacture of 3D doors, one of which you can see in the title photo.
Many manufacturers produce exclusive series of doors made in a certain style: antique, Italian, country, French. You can also make doors according to the design project for finishing a house or apartment, developed by a designer.

Note! With an insufficient volume of output, a workshop working with solid wood can be focused on the production of decorative trim, cornices and sandriks, shutters for windows. The company can expand its product range by manufacturing garden and home furniture, and even take orders for interior decoration with wood.

But the main direction, of course, should be the production of entrance and interior doors. Such products are always in demand, and the main thing here is to offer the consumer not only the best price, but also a variety of front finishes.
You need to focus not only on single, but also on one and a half and two-leaf doors. After all, making double-leaf doors with your own hands is not an easy task, and a person who needs just such a door, in any case, turns to the manufacturer.
The successful sale of products in a retail network is ensured not only, and not so much by the appearance of the product, but by its compliance with standards. What is the use of a beautiful door if it does not fit into the opening? So, the manufacture and installation of doors is a responsible matter, requiring not only creative imagination, but also geometric accuracy.

Doors made of solid wood are not cheap, and the range must include economy-class products. In the production of such doors, MDF is used, as well as pine - as the most affordable and inexpensive tree. In the manufacture of budget doors, these two materials are often combined.
In frame-panel doors, the strapping of the leaf can be made of pine bars. To make the door light, the frame is filled with a special honeycomb material, which is pressed corrugated cardboard or hardboard.

To give such a canvas the proper look, they use sheet material that is cheaper than natural wood: fiberboard, chipboard, plywood, MDF. The canvas is sheathed, then laminated or ennobled with veneer (see).

From MDF, by the way, you can make door linings, as well as panels. Moreover, cheap doors can be made of unfinished material, and intended for painting.

Types of structures from the array

Doors are made from different lumber. And the right technology for processing the structure allows you to get a quality product at a low cost.

For the production of a door leaf from an array, the following are used:

Plywood. In this case, thin sheets of wood are glued together on a press with synthetic resins. Advantages of structures: strength, resistance to mechanical stress, durability, low cost. The disadvantage of products is the use of a resin-based adhesive;
One piece board. This is the most expensive type, requiring constant care for the doors and their timely processing.
MDF. They are made from waste lumber, processed and pressed on a special machine. Advantages of the material: the optimal dimensions of the product, the thickness of the web can be from 4 to 22 mm, high hardness, moisture resistance, does not deform. Minus - the use in the manufacture of resinous adhesive compositions that emit phenolphthalein.

The quality of a solid wood door is greatly influenced by the type of wood used to make it.

Tree varieties

The table shows the most commonly used for the manufacture of doors, wood species and its features:

wood species	Peculiarities
	The main advantage of pine doors is affordable cost. Disadvantages of such doors: The softness of wood; Low resistance to moisture and temperature changes; The last shortcomings can be eliminated by modern methods of manufacturing and finishing doors: glued rather than solid pine is used for production. In this case, the different direction of the fibers in one product improves the performance of the design.
	The main advantage of alder doors is high resistance to moisture. Besides: Alder has healing properties - it contains many tannins that have a beneficial effect on human health; Alder contains a small amount of various resins; The material does not smoke during combustion, does not emit harmful substances into the air. Since ancient times, this wood has been used for heating baths; Such products are ideal for the street and rooms with high humidity.
	This is a strong, hard and fairly heavy wood species used for the manufacture of relatively inexpensive doors. Advantages of walnut structures: very beautiful and original structure, which can be given any color. In addition, the walnut can be perfectly polished, in this respect the material cannot be compared with any other tree.
	These are the most expensive among similar products. Designs: heavy; durable; durable; Have a unique structure; Excellent resistance to changes in humidity and temperature; They have unsurpassed heat and sound insulation properties; Do not warp and do not change their original dimensions; Difficult to process.
	Merbau doors in appearance resemble pine, but their quality is better. durable; durable; Resistant to moisture; Do not crack when dry. This is due to the fact that inside the wood there is a large amount of oils that create a strong protective film on the surface of the canvas.
	Maple canvas has a reddish or light yellow tint. During shrinkage, the material does not crack, it shrinks slightly. This is a fairly robust design that is not afraid of mechanical stress. When purchasing a maple door, you should keep in mind that the wood changes its color when it falls at different angles.
	Aspen with an orange tint in any design looks rich. The material is not afraid of moisture. Mechanical finishing lends itself poorly, due to the high density of the material.
	Ash doors are distinguished by an unusually bright wood pattern. The color of the product is from whitish-yellow to honey. In terms of strength and durability, the structures are similar to oak. But they are soft, which makes it easier to work with the canvas. When dry, the doors crack minimally. They tolerate temperature changes well.
	Beech color is pinkish, light shade. The wood is hard and difficult to process. Practically does not absorb moisture. In terms of strength and appearance, it is not inferior to oak, as seen in the photo.

Solid wood doors can be made from almost any wood. Using modern tools, many manufacturers, giving inexpensive wood a certain color, produce a product from valuable species. It is impossible to determine the type of wood by eye.

Tip: When purchasing solid wood doors, preference should be given only to trusted manufacturers who have a sufficient number of positive reviews.

It should be borne in mind that "solid doors" are not made from solid wood, such as walnut. This is technically incorrect: such a “product” will not stand for even one season, it will lead, the geometric dimensions will change. In addition, it is difficult to imagine the diameter of the tree required for the manufacture of the door.
For the correct manufacture of a product from an array, a “furniture board” is used, and not a single piece of wood.
The furniture board is wood glued together across the width. In this case, presses and high-quality glue are used. The quality of the manufactured shield affects the operational properties of the door.

The most crucial moments in the manufacture of furniture panels are:

Drying. This is one of the main operations in the production of the shield. The wood must be thoroughly dried to prevent future deformation of the product associated with changes in humidity and temperature;
Glue. The strength of the connection is directly affected by the quality of the selected adhesive;
Fiber direction. This is of great importance. They should be in each lamella perpendicular to the fibers of the next. This will give strength to the shield, and prevent any deformation of it.

Door classification

Before you start making a door with your own hands, you should get acquainted with their classification. This will help you choose the most suitable option, depending on the characteristics of the doorway and the operation of the structure.

According to the operational purpose, doors can be:

Interroom. Made from wood. They are much thinner, they do not have great requirements for safety, heat and noise insulation;
Entrance street. Such structures separate the house from the outside world. The requirements for them are higher. Most often, they are made of steel, which is finished with natural wood or MDF.
Entrance apartments. Despite the fact that these doors are entrance doors, they are operated as internal ones, since they do not come into contact with the street.

According to the design of the door can be:

Single, consisting of one canvas. Are established in a doorway which width is up to 100 cm;
One and a half, consisting of two canvases, of different widths. One of the canvases, as a rule, opens only when necessary, and is fixed motionless;
Double, consisting of two canvases of the same width.

According to the device and production technology, door leafs are:

Paneled. This is the most complex and expensive option to manufacture, which is a frame with internal inserts located in it, called panels. For their manufacture, various materials with a wide range of shapes are used. The elements are connected to the frame using the tongue and groove system. To give a beautiful appearance, glass panels are inserted into the canvases. often used as input, subject to the device of a reinforced frame;
Shield. These are the simplest and cheapest designs to manufacture. Such a canvas consists of a wooden beam or chipboard frame, which is sheathed with veneer.
Keyed. For their manufacture, several matched identical bars are used, interconnected by a key, which can be a wooden bar or a forged steel strip. Such doors are used more often in rural areas for utility rooms.

Door manufacturing

Solid wood doors are manufactured according to the standard scheme. Differences can only be in the material and installation of fittings.

Tip: Before starting work, you must choose the right boards for the frame. They should not have defects, be smooth, normal humidity.

After purchase, the boards should be kept indoors for several days so that they adapt to the microclimate of the room. Then the tool is prepared for work.

For the manufacture of a structure from an array, the following equipment is required:

Circular saw or electric jigsaw;
Manual milling cutter, for cutting grooves;
Grinding machine or nozzles for an electric drill or grinder, with sanding paper;
Electric drill, screwdriver;
Chisel, screwdrivers;
Ruler, tape measure, square, pencil.

From the materials you will need:

Board, section 150x40 mm.

Tip: It is better to purchase boards with a margin, which can be useful in case of errors in the processing of materials, so that the boards are from the same batch, the same humidity.

Joiner's glue;
Confirmations or dowels;
Solid wood for panels.

Work instructions:

Drawings are being prepared for solid wood doors and frame elements. At the same time: boards of measured length are cut, wide parts are polished. It does not make sense to do this from the ends - they will be milled at an angle;
Chamfers are removed with a milling cutter, a groove is cut out 20 mm deep and 16 mm wide, along the entire length of the board, strictly along its middle;
To connect the end boards, their ends are cut at an angle of 45 °. Details are applied and adjusted in place;
Panels of the required sizes are made from solid wood;
Pre-assembly of the structure is in progress;
Possible deviations are identified, which are corrected before the final assembly of the doors;
After checking all the dimensions of the assembled structure, the door is finally assembled on the confirmers. Before that, all connection nodes are smeared with carpentry glue;
Fittings are installed.

To properly assemble the door from the array, you should watch the video in this article.

How to equip a workshop for the production of room doors

We have made a general description of the manufacture of doors - in any case, it is quite clear what materials are needed for this. But what kind of equipment is required for this? Instructions on this topic will be presented below.

Milling machines

Opens a list of equipment for a milling machine, without which it is impossible to either process profiles normally or perform surface milling. Industrial milling machines are equipped with a vacuum cleaner that immediately removes dust and chips. With the help of such a machine, you can cut spikes, make a selection of grooves, and even make skirting boards.

But there are also special devices designed for installation on a router that can turn it into a universal mechanism for woodworking. Take, for example, the manufacture of door linings, or the implementation of a three-dimensional relief, which is now called a 3D profile.

There are many varieties of milling machines, but basically, in the door industry, they use a variant with a numerical programming device, abbreviated as CNC. If you need to carve wood, then you need a milling and engraving machine, also equipped with a CNC.
Such equipment is equipped with a microprocessor, has RAM, which makes it possible to program. It does a great job of multi-tasking, increasing shop productivity, and saving time – and therefore money. Industrial equipment is expensive, so for starters, when opening a small workshop, you can get by with a manual machine.

By the way, it can be simply indispensable when you need to make narrow grooves or small decorative elements. With a manual router, you can make a beautiful door yourself. It is enough to type in the search line: making doors with your own hands video, and watch a few training videos.

You will also need a milling and copying machine, which allows you to make several absolutely identical or symmetrical blanks. It is of high quality processing, and can work with both flat and volumetric parts.

The second in the list of equipment is a thermal vacuum press, with the help of which hot pasting of the door leaf with a laminating film is carried out. There are models designed only for furniture facades, and there are options for pasting door panels and linings on them - or universal ones that can be reconfigured if necessary.

The press can have one or two tables, the size of which is at least 2.1*1.0m. These dimensions are the most optimal, since the larger the table, the more decorative film is consumed. And this is unprofitable for the manufacturer, especially since films of the "chameleon" type, or with photo printing, are very expensive.

Sizing machine

The third type of equipment that you need to have in the manufacture of doors is a panel saw. It is designed for both piece and batch cutting of blanks of a given size.

With the help of such a machine, sheet and long materials are cut - not only wooden, but also composite, as well as lined with veneer, PVC film, laminate, and even plastic.

A professional sizing machine is needed regardless of the scale of production - whether it is a furniture factory or a private carpentry workshop. Thanks to the possibility of batch cutting of blanks, it makes it possible to significantly reduce the production time, and, accordingly, increase the pace of production.

plastic doors

If we talk about the manufacture of plastic doors, then everyone knows very well that the manufacturers of these products are also focused on windows - you can even say that they are mainly windows. They are put everywhere, and they make up the lion's share of the assortment of any enterprise of this type.

Both internal and, but they are increasingly placed in institutions and offices are in demand. In the residential sector, the main type of plastic doors are balcony doors. As in any production, here, too, you need to strive for the highest quality result. To sell PVC doors, manufacturing and installation technology must strictly comply with existing standards.

This also requires a certain set of equipment, and qualified personnel. Here we mean not only the workers who directly assemble the products, but also the measurers and managers involved in the logistics of the workshop - after all, you cannot get a high-quality product from low-quality material.

With the right approach to organizing a business for the manufacture of plastic windows and doors, the enterprise will certainly be profitable, since the profit always exceeds the expenditure side. Of course, for this you need to deeply study the market, find a suitable premises, and invest in advertising. All these are expenses, but due to the demand for this product, they quickly pay off.

Equipment and materials

As for the equipment, then here is your list. First of all, these are saws for cutting a reinforcing profile, which is inserted into a plastic profile to stiffen it. They are fastened together with pneumatic screwdrivers. Naturally, a compressor of the appropriate power is also needed to supply compressed air.

Note! So that condensate does not form and accumulate in the internal cavity of the profile, holes are drilled in imposts, frames and sashes. For this, a drainage machine is used - although this can also be done with a drill.

So:

In the production of plastic windows and doors, one cannot do without a machine designed for welding profile corners. The sagging formed after welding is removed using a cleaning machine, which can be either manual or included in the automated line.
Before installing the impost into the frame profile, its ends must be milled. For this purpose, a face milling machine is used, which can be desktop, and have mechanical clamps, or stationary, with pneumatic clamps.
Well, for the convenience of work, auxiliary equipment is used, which include containers for storing blanks, carts, and assembly tables. For a small workshop with a capacity of up to ten products per shift, you can purchase the necessary equipment as a kit. It includes manual machines and desktop tools.

In addition to those that have already been mentioned, the kit contains: an electric planer, with which surfaces are cleaned; swallow tool, necessary for cleaning the outer corners; a template used for symmetrical drilling of holes - as well as tools for milling drainage channels at angles of 45 and 90 degrees. There are nine pieces of equipment in total, the total cost of which is approximately 130,000 rubles.

Technological procedure for assembling PVC doors

The process of assembling windows and doors from a PVC profile is largely identical, but the doors still have some features.

In general, the assembly looks like this:

First, metal and plastic lengths are cut to size. By the way, the door profile differs from the window profile in section. When opening from the outside, it has a T-shape, and when opening from the inside, it has a Z shape. This nuance must be specified in the order.
At the second stage, drainage milling is performed required to ensure that condensate is drained. This is done in both window and door profiles.
Further, a metal profile is inserted into the plastic profile, holes are immediately prepared for the strips, handles and locks. On entrance doors, the lock may have a push handle, in office versions - a bracket.
The next operation is cutting to the size of the impost, and milling its ends. Upon its completion, they begin to perform all the connections carried out mechanically. After that, the frame and door profiles are welded, and their surface is cleaned.

If the door is with a threshold, the next step is to assemble it. The threshold is cut to size, a gasket is installed on it, then a connector. Now, an impost is mounted in the door leaf, and a sealant is placed on the threshold.
Next comes the moment of attachment to the canvas of the loops, which is carried out using a template. The hinges adjust, install a handle or a lock, fix a reciprocal bar on the frame. It remains only to install a double-glazed window, and the door is ready for delivery to the customer.

After making sure that all the fittings are functioning normally, the handles, the push fitting and the lock cylinder are removed. This is necessary to avoid damage in transit.