Without the use of ink, Seamless Inlay is all done with two sheets of contrasting laminate paper. You can create a solid and a pattern, or combine two patterns (like a woodgrain with a marble inlay). The result is a single laminate with the appearance of expensive inlay, without seems or voids between the patterns. Seamless Inlays are used today in movie theatres, offices, and other buildings where bold and innovative design is desired. To be most cost effective, the project should incorporate at least fifty doors due to laminate set-up and production.

For more intricate designs or for designs that entail multiple colors or require exact color reproductions, the Silk-Screen process is more suitable. Here, a design is screened directly onto a sheet of decorative paper, which is then made into a laminate surface. The result is a smooth, solid finish, with a design that is protected from scratching or peeling. Logos and artwork that require bright, detailed graphics come out beautiful and exact with the Silk-Screened process. This process is more expensive than the Seamless Inlay process but delivers more customization.

When "picture perfect" is the expectation, the Graphic Image process is the best bet. A full-color photographic image or original artwork is scanned into a computer and transferred onto the decorative paper. It is then turned into laminate surfacing material. The capabilities are virtually unlimited, with amazing clarity and dimensionality, and the Graphic Image is as durable as standard laminate. This is the most costly of the Custom Laminate processes due to the time it takes to digitize the image and scan to the paper. As with any new technology, however, laminate manufacturers expect the speed and efficiency of this process to continue to improve and to be very cost effective for large production runs.

TEXTURES AND OPTIONAL FINISHES

While a matte finish is considered the standard for most decorative laminate finishes, aesthetic considerations demand several new and innovative options. Laminate manufacturers offer several textures. The textures help minimize smudges and finger marks, enhance reflective qualities, and even reproduce the sheen associated with waxed wood furniture. New embossed patterns add the look and feel of true flat cut wood while a pebbled texture adds the look and feel of course grained sand.

DECORATIVE LAMINATE DOOR CONSTRUCTION

The primary difference between laminate-clad wood doors and wood veneer-faced doors is simply the face material. Decorative laminate doors are usually 1 3/4 inch commercial-grade thickness and available with the same core options as wood veneer doors including particleboard, staved lumber, structural composite lumber (SCL), and mineral core doors (with fire ratings up to 90 minutes). Decorative laminate doors are produced with both hot press and cold press technologies, depending on the manufacturer's capabilities. Doors are either 3-ply or 5-ply construction. Laminates with textures producing a moderate or low gloss are candidates for 3-ply construction, provided that the manufacturer has the capabilities to sand the core assembly as a single monolithic unit. Otherwise the core may "telegraph" through the face laminate and distract from the aesthetic appeal of the door. Fire rated doors and doors with high gloss laminates require crossbands, creating a 5-ply construction.

Standard laminate thickness to meet the Window and Door Manufacturers Association (WDMA) quality standards is 0.050 inch (1.3mm). Occasionally, specifications call for 0.125 inch laminate. With today's advanced technology, 0.125 inch laminate is typically unnecessary. The door edges are usually finished with the same laminate as the face. Laminate edges should be applied before the face laminate to "lock in" the edge strip for durability and to prevent chip-outs. Also, the edge-before-face design conceals the seams for a more attractive appearance. In some cases, the edges will be painted or stained, either in the factory or at the job site. However, factory finishing is highly recommended for a more consistent and uniform finish.

Most manufacturers have the capability to factory machine doors for commercial hardware preparation. This prepares the doors for quick and hassle-free installation at the job site. Some manufacturers include pre-drilled pilot holes for hinges and face plates, which reduces time and prevents splitting the stiles during installation. Decorative laminate doors should have the top and bottom rails sealed at the factory like any finished door, to protect against moisture damage and warping. As with any completely finished product, proper packaging is important. It is recommended that each door be individually poly-bagged and then palletized for either factory truckload or LTL shipment requirements.
Most manufacturers offer the same product warranty on decorative laminate doors as wood veneer doors. Many offer lifetime-of-the-structure guarantees, and some include reasonable rehanging costs.

DECORATIVE LAMINATE WOOD DOORS COMPARED TO WOOD VENEER DOORS

Architects and building owners have long associated decorative laminate doors with durability and uniformity of appearance. Today, however, decorative laminate doors are additionally recognized for creative design, easy maintenance, and overall value. Consider:

DECORATIVE LAMINATE WOOD DOORS FOR DESIGN, DURABILITY AND VALUE

Combine all the feature of high pressure decorative laminate doors, and the benefits are obvious to the architect, designer, general contractor, door distributor, and building owner. Creative, beautiful, and durable. The possibilities are wide open.