How PVC Doors Are Made from Raw Materials

PVC doors have become a mainstream material for residential and commercial buildings due to their durability, moisture resistance and cost-effectiveness. However, behind every stylish and modern PVC door, there is a complex and rigorous manufacturing process. From PVC resin raw materials to assembled doors, this transformation process involves precise extrusion, reinforcement, surface lamination and hardware integration.

We break down the full journey of how a PVC door is made—from raw material processing to final assembly and packaging.

1. What Is a PVC Door?

PVC, or Polyvinyl Chloride, is a thermoplastic polymer widely used in construction. In doors, it is typically utilized in a rigid form known as uPVC (unplasticized PVC). PVC doors are popular for:

• • Moisture resistance (ideal for kitchens, bathrooms, balconies).

• • Thermal insulation.

• • Soundproofing.

• • Low maintenance and long life.

The structure of a PVC door may include:

• • A hollow multi-chambered PVC profile.

• • Metal reinforcement inside the frame.

• • Decorative or protective surface films.

• • Optional glass panels or foam fillings.

2. Raw Material Preparation

2.1 PVC Resin and Additives

The manufacturing process begins with high-grade PVC resin, which looks like a fine white powder. To create a durable, stable profile, the resin is blended with several additives:

The blend is mixed in high-speed blenders, ensuring uniform dispersion of additives.

3. Extrusion of PVC Profiles

3.1 Heating and Shaping

The mixed powder is fed into an extrusion machine, where it’s melted and pushed through a steel die that forms the desired profile shape. This includes:

• • Door frames

• • Door leaves

• • Mullions (if applicable)

The process involves:

• • Controlled temperature zones (150–200°C)

• • Twin-screw extruders for even melting and mixing

• • Die shaping that defines thickness, hollow chambers, and grooves

3.2 Cooling and Calibration

After exiting the die, the hot profile enters a calibration table with vacuum and water cooling systems. This sets the exact dimensions and wall thickness of the profile while rapidly solidifying its structure.

4. Surface Treatment and Lamination

4.1 Surface Preparation

Before applying decorative films, profiles are cleaned and sometimes treated with primer to ensure strong adhesion.

4.2 Decorative Foil Lamination

PVC profiles may receive laminated foil to simulate wood, metal, or matte textures. This is done using hot-melt glue and heat rollers. Common patterns include:

• • Oak or walnut woodgrain

• • Brushed aluminum

• • Matte white or grey

Laminated profiles are UV-resistant and scratch-proof, ideal for long-term aesthetics.

5. Cutting and Welding

5.1 Precision Cutting

Profiles are cut to exact lengths based on door specifications using automatic saws with accuracy down to tenths of a millimeter.

5.2 Welding Corners

At this stage, four cut pieces (two vertical stiles and two horizontal rails) are heat-fused at the corners using a welding machine. This ensures:

• Air- and water-tight corners

• Strong structural integrity

• Perfect rectangular geometry

Post-welding, the corners are cleaned using corner cleaning machines to remove excess material and smooth the joints.

6. Reinforcement Installation

Although PVC itself is lightweight and durable, large door frames require internal support. Steel or aluminum reinforcement bars are inserted into hollow chambers within the profiles. These provide:

• • Enhanced rigidity

• • Resistance to wind pressure or impact

• • Support for heavy hardware like hinges and locks

The reinforcement is fixed with screws or rivets during assembly.

7. Panel and Glazing Options

7.1 Solid Panel Doors

For non-glass PVC doors, the leaf may be filled with:

• • PVC foam board for lightweight strength

• • MDF inserts or WPC boards for enhanced insulation

• • Honeycomb paper for economic interior doors

7.2 Glass Panel Doors

If the door design includes windows:

• Glazing beads are inserted to hold the glass securely.

• Glass may be double-glazed, tempered, frosted, or decorative.

• Sealant strips ensure airtight and watertight closure.

8. Hardware Preparation

The next step is routing and drilling for locks, handles, hinges, and cylinder holes. This is often done with CNC machines for consistent and accurate positioning.

Depending on the door model, hardware may include:

• Multipoint locking systems

• Anti-theft locking hooks

• Soft-closing hinges

• Lever handles or knobs

• Thresholds and magnetic seals

All components are installed manually or semi-automatically, and tested for function.

9. Quality Inspection and Testing

Before packaging, each door goes through inspection checkpoints:

Doors that don’t meet standards are reworked or rejected.

10. Packaging and Shipping

PVC doors are cleaned, wrapped in protective plastic film or foam sheets, and labeled with:

• Model name

• Dimensions

• Finish

• Hardware configuration

For export, doors are palletized and shrink-wrapped to prevent moisture damage or impact during transit.

11. Installation Considerations (On-Site)

Though not part of factory manufacturing, proper installation is critical for performance:

• • Doors must be installed in plumb, level frames

• • Gaps should be sealed with weather-resistant silicone

• • Expansion allowances are left around the frame

• • Final alignment ensures smooth swing and lock engagement

Manufacturers often provide installation manuals and videos for professional installers.

Why It Matters

Every step—from resin blending to foil lamination and hardware testing—ensures that a PVC door:

• • Stays dimensionally stable in worse weather

• • Offers better moisture and termite resistance

• • Delivers long-term durability with minimal maintenance

• • Matches various aesthetic styles with color and texture options

When these processes are executed with precision, the final product is a high-performing door that meets both functional and decorative demands.