The layup process begins the same for both doors with the assembly of the wood frame. All corners are mitered leaving no butt edges on the door. This creates a stronger more durable corner. The wood lock-block is then stapled to the frame and the foam is placed inside. Before the steel/composite skin is connected the door is looked over to make sure everything is fitting tightly.

From here the process is split… 

Steel Process
The door skin is placed on the frame and tamped down to create a tight fit. Once it is tamped, the door, along with 25 others are put into a press and will stay there for 1-3 hours. 

Composite Process
The frame and foam are put through a hot melt press, once there is glue on both sides the composite faces are placed on the top and bottom and the full door is put through a press. Here all the voids in the glue and seems are pressed out of the door.