Reeb Interior Doors – Reeb Learning Center

Molded Hollow Core Doors

Hollow Core molded doors offer a lighter-weight, economic alternative to wood stile and rail interior doors.

Construction

Molded Doors are constructed as two skins separated with lightweight materials in the middle. The skin, or face, of the door is a 1/8” molded hardboard skin that is available with a smooth or textured painting surface.

Smooth Skin

Texture Skin

Core

In between the skins is a hollow core which includes blocking. This provides support for the door skins, but does not provide any sound insulation.

Hollow Core Blocking

Stiles and Rails

Along the vertical edges of the doors are wood or MDF stiles. Hollow core doors are available with medium density fiberboard (MDF) stiles as the lowest cost option. Wood stiles are preferred for better durability and strength. Along the top and bottom is a single fiber rail.

Single Bottom Rail

Conclusion

Molded hollow core doors come in a variety of styles and sizes. They are a great alternative to stile and rail doors however do not offer a high level of durability.

Molded Solid Core Doors

Solid Core molded doors are used in a variety of residential and light-commercial interior applications.

Construction

Molded Doors are constructed as two skins with a core in the middle. The skin, or face, of the door is a 1/8″ molded hardboard skin that is available with a smooth or textured painting surface.

Smooth Skin

Texture Skin

Core

In between the skins is a solid core that is routed to match the skin’s design. A solid core gives the weight and feel of a real wood door and reduces sound transmission. The 1-3/4” doors are able to carry a 20 minute fire rating when placed in the proper frame.

Solid Particle Core

Stiles and Rails

Along the vertical edges of the doors are wood stiles which allow for extra screw holding power. Along the top and bottom of the doors is a single rail for 6/8 doors and either a double or triple rail on larger or thicker doors. The benefit of a double or triple bottom rail is that it can be field trimmed, however, this may affect the doors fire rating.

Single Bottom Rail

Conclusion

Molded solid core doors come in a variety of styles and sizes. They are a great choice for residential applications like living rooms, bedrooms, hallways and large storage areas.

Molded and Flush Door Manufacture Process

Molded doors are used in a variety of residential interior applications. They feature four primary components – door skins, cores, stiles and rails. After receiving all the materials, the production process can start.

A picker will gather the items needed for an order. The solid core is routed to the door’s design so the skin can fit properly and the skins are cut to size.

The stile and rail pieces used come in standard heights and widths, however the lock block necessary for the doors must be cut to size. If any doors are special order to a non-standard size, the skin and core must be cut to the proper width and height.

All skins arrive face up; during the final assembly process there is a lot of glue used which could potentially damage the face of the skin. Therefore, the skins are organized face to face for ease during assembly. Recessed panel doors will have a space where the two opposing recessed panels come together. For that reason, a piece of foam is placed in the panel area to help distribute the pressure.

All the pieces and parts make their way to assembly. Here the components go through a glue machine and are then arranged on top of the door skin and a matching skin is placed on top to complete the unit.

Once a stack of doors is assembled, they move into a press. The doors are pressed for 30 minutes in a cold press; this is the point of the process where the foam previously placed in the panel area is very important. The doors then sit in a drying area until the glue is fully dries. Dry time varies between 10 and 24 hours.

A sizer machine trims the edges of the door. The first cut will trim the width and the second cut will trim the height. To cover the freshly trimmed portions, the doors travel through a priming machine. Drying tunnels with heaters and fans help to dry the doors quicker. A buffing station will then make the edges smooth.

Some of the doors move over to be packaged for bifold units. The doors are wrapped to keep them on the pallet. Finally the doors are staged and readied for loading into trucks for shipping.

Ovation MDF Doors

Ovation doors are crafted from components made of medium density fiberboard. The wood- based material will not split or warp and provides a smooth paintable surface. The one piece face ensures no stile and rail separation. They are constructed with patented Integra-Lok stiles for maximum screw holding performance. Designs include a solid raised or flat panel designs. The Fiberfuse process bonds the pre-machined sheets into a layered composite under extreme pressure. Exterior grade type one glue is utilized for strength and durability.

Features

146 standard designs, plus custom flexibility
Integra-Lok wood edge for screw holding strength
Uniquely layered construction
Factory primed on all six sides, ready to start the finishing process
Made in the USA by proud American craftsmen
Limited Lifetime interior warranty

Ovation Door Profiles

Ovation Doors feature no, round, square, or ogee sticking. They can also include chalkboard, dry-erase or mirror sections as well as a glass entity.

No Sticking

Ogee Sticking

Round Sticking

Square Sticking

Chalkboard or Mirror on One Side

Chalkboard or Mirror on Both Sides

1/4″ tempered glass lite

1-3/4″ ovation (shown with 1/4 round sticking) – 1/4″ tempered glass lite

Bolection Molding

Ovation Doors have an option to include bolection moldings which are inlaid around the edge of the door panels. They are available as large or small.

Small

Large

Click here to see the Ovation Door Bolection Molding profiles.

Louvers

Louvers are available in a venting or false louver option. The venting option allows for air flow, and will need to be specification as to where the blind side will be facing (towards the hinge side or the stop side).

Venting

False

Door Layouts

The Ovation Door is in the 7000 series.

Encore MDF Doors

Encore doors are router carved to exact tolerances by CNC computer driven routing equipment. They are constructed of laminated MDF with patented Integra-Lok stiles for maximum screw holding performance. The face of the door is one piece to ensure no stile and rail separation. The panel detailing is router carved for a raised panel definition. The core provides a sound deadening ability which adds privacy to any room.

Features

152 standard designs Available
Available with foam core or optional solid MDF core
Foam core gives and architecturally correct door weight consistent with stile and rail doors
Available 1-3/4” or 1-3/8” thick
Integra-Lok stiles for screw holding performance
Dramatic raised panels or grooved options
No possibility of stile and rail separation
Traditional molding profiles
Solid surface construction
Factory primed on all six sides, ready to start the finishing process
Special order designs possible
Custom design flexibility
Made in the USA by proud American craftsmen
Limited Lifetime interior warranty

Foam Core or Solid MDF core

Encore doors can be manufactured with either a foam or a solid core in the door.

Solid Core

Foam Core

Encore Door Profiles

Encore Doors feature either the Ogee or Standard profiles. They can also include chalkboard, dry-erase or mirror sections.

Standard

Ogee

Chalkboard and Dry-Erase

Mirror

Door Layouts

The Encore Door is in the 6000 series.

Bravo MDF Doors

Bravo MDF doors are built exactly like wood doors were made centuries ago with the traditional doweled stile and rail construction. Separate stile, rails, and panels are assembled by hand utilizing twenty-first century technology. They are constructed with wood stiles for screw holding strength and from highly refined MDF which is a stable and abundant wood fiber material. They are available with a solid raised or flat panel design. The wood dowels ensure against stile and rail separation.