The Making of a Membrane Door

Modern architecture and interior design make doors no longer just functional elements—they are statements. They define spaces, set the tone for aesthetics, and even influence energy flow in a room. Among the most innovative door solutions today is the membrane door. This sleek, versatile, and durable option blends form and function seamlessly. But how does a membrane door evolve from a concept to a finished product? The journey is as fascinating as the door, involving modern technology, meticulous craftsmanship, and a deep understanding of design principles.

SPLICE PLY doesn’t manufacture doors; we create experiences. Our membrane doors result from years of research, innovation, and commitment to excellence. Whether you’re an architect, interior designer, or homeowner, understanding the process behind a membrane door will help you appreciate the artistry and engineering incorporated into every SPLICE PLY product. In this article, we’ll take you behind the scenes, step by step, to show you how we transform raw materials into doors that redefine spaces.

The Big Idea: Where It All Begins

A beautiful door begins with a vision. Splice Ply’s vision is to design and manufacture doors that look good and are durable. Here’s how the concept takes shape:

• Customer Needs Come First: We listen to homeowners who want low-maintenance beauty, designers craving unique styles, and contractors needing reliability. Feedback drives everything.
• Material Matters: We used top-grade plywood as the base—strong, stable, and ready to hold up the door’s structure. Then comes the PVC membrane, a tough, flexible layer that’s the secret to durability.
• Sustainable Approach: Sustainability isn’t an afterthought. We aim for low-emission materials, like E1-rated plywood, to keep the planet—and your conscience—happy.

Designing the Blueprint: Planning for Perfection

Once the idea’s solid, it’s time to draw up the plans. This is where the rubber meets the road, where the pencil meets the paper. Splice Ply’s design process is meticulous, and here’s what takes into it:

• Shape and Size: We map out exact dimensions to fit your space, whether a grand front door or a sleek interior panel.
• Style Choices: The PVC membrane gets customized from bold colors to subtle textures. Want a wood-grain look without the upkeep? We’ve got you covered.
• Strength Testing: We run virtual stress tests—think heat, humidity, and wear—to ensure the design holds up.
• Functionality First: Doors need to swing smoothly, seal tight, and stand firm. Every hinge point and edge is planned.
• Feedback Loop: Designers tweak the blueprint based on real-world input from architects and builders who know what works on-site.

The Build: Turning Plans into Reality

Now comes the fun part—making the door. Splice Ply’s factory is where ideas become physical, and it’s a precision process. Here’s how it happens:

• Cutting the Core: High-quality plywood is sliced to a laser-like size. No room for error here.
• Preparing the Surface: The wood gets smoothed and primed, setting the stage for an ideal bond.
• Added the Glue: A unique polyurethane adhesive is spread evenly. It’s flexible enough to handle wood’s natural shifts without cracking.
• Laying the Membrane: The PVC sheet, cut to match, is placed on top. This layer makes the door challenging against water, bugs, and the sun.
• Heat and Pressure Magic: Into the press, it goes—150-200°C of heat, and firm pressure melds the membrane to the wood. It’s a tight, unbreakable hug.
• Cooling Off: The door rests as it cools, locking the bond in place for good.
• Finishing Touches: Edges are trimmed, surfaces polished, and hardware-like hinges are added. Ready for action.

Why It Works: The Science of Strength

So why do these doors last? It’s not luck—it’s science. Splice Ply focuses on what makes membrane doors stand out. Check out the key factors.

• Waterproof Power: PVC doesn’t soak up water as wood does. Spills, rain, humidity? No problem.
• Bug Blocker: Termites hate PVC. The membrane keeps them out, saving wood inside.
• UV Shield: Sunlight won’t fade or weaken the surface, thanks to UV-stable additives in PVC.
• Wear Resistance: Daily bumps and bangs don’t faze it. The membrane spreads out stress.
• Bond That Holds: That heat-pressed bond doesn’t peel or flake, even after years of use.
• Flex Factor: The adhesive lets the wood breathe and move without breaking the seal.
• Low Maintenance: Wipe it down, and it’s good. No sanding or repainting is needed.

Why Choose Splice Ply? Your Door, Your Way

Our membrane doors are built to outlast the competition, with a style that turns heads and toughness that takes on anything. Homeowners get a hassle-free upgrade that looks great and stays that way. Designers and architects have endless options to bring their visions to life. Contractors save time and headaches with doors that install quickly and last forever. Plus, our eco-friendly approach—low-emission plywood and sustainable practices—means you’re doing right by the planet. Ready to see the difference?

Contact Splice Ply today. Call us, email us, or visit spliceply.com to explore our range.