Opanpan Door Skins
MDF doors are the current mainstream interior door options. They have always been popular among consumers because of their advantages such as good quality, low price, various styles and comprehensive features.
According to official statistics from the North American Decorative Materials Association, from 2018 to 2012, among common interior door options such as solid wood doors, aluminum alloy doors, and PVC doors, the sales volume of MDF doors has always been in the top two positions, which shows its popularity.
This article will explain various aspects of MDF doors to readers from three aspects——the production process of MDF doors, advantages and disadvantages, and the comparison between MDF doors and solid wood doors.
Finally, this article will also objectively analyze the market performance and price of MDF doors.
The main material of MDF wooden door—MDF
Before introducing MDF wooden doors, we need to first understand MDF. Many advantages of MDF wooden doors are closely related to its main raw material MDF.
- What is MDF？
MDF stands for Medium Density Fiberboard, an engineered wood product. Made by compressing hardwood or softwood fibers with resins and waxes under high temperature and pressure, it is denser than plywood and particleboard. Since its raw materials come from recycled and reused wood fibers, MDF is a more affordable and durable alternative to natural wood. Because it resists cracking, warping, expansion, shrinkage, and splitting, it is often used in the construction of residential and commercial doors.
It also provides a smoother surface than many types of wood. In the process of making MDF, MDF is compressed to a high density in a hot press, ranging from 31 to 50 pounds per cubic foot, and the inter-fiber bonds are made using organic adhesives or synthetic resins throughout, which gives it high strength and durability.
- Both are boards made by crushing wood fibers and pressing them into shape. What is the difference between MDF and particle board?
MDF has a more uniform and compact density. MDF with a higher density is called HDF. Workable edges. MDF has tight, smooth edges that can be finely processed with tools such as whittling, punching, and carving. Smooth surface. The surface of MDF is very smooth, eliminating the need for laminates and additional veneers. Thicker MDF panels, ranging from 1/2 inch to 3/4 inch, are often used as core materials for furniture panels. MDF panels less than 1/2 inch thick are often used for siding.
- Why is MDF called an environmentally friendly board?
MDF has a lower environmental impact: Wood products don’t require as much energy to manufacture as most other building products. They don’t produce as many environmentally harmful byproducts and can be recycled or reused. They also have a lower environmental impact over their lifespan.
MDF is biodegradable and renewable: MDF, like all wood products, is 100% biodegradable once its lifespan has ended and comes from a 100% renewable and sustainable natural source. This is not the case with concrete, plastic or metal.
MDF door skin production process
The production of MDF door skins is different in different parts of the world. Below we will take the production process of OPANPAN’s latest MDF door skins as an example to explain it to you.
Sawdust stage
The furnish of MDF is wood chips. This material is usually shipped by rail or truck from plywood mills, sawmills, satellite chipping plants, whole tree chipping operations, and other off-site locations. In some facilities, wood chips are prepared on-site. In this case, the logs will be debarked, cut into more manageable lengths, and then sent to the chipper. If necessary, the chips can be washed to remove debris.
The wood chips are then placed in a steam-pressurized digester where they are softened. They are then placed in a refining chamber where rotating disks turn the softened chips into a wood fiber material that can be used to make boards. Next, the fibers move to a drying area. Sometimes the wood chips are first dried in a rotary predryer, but in any case, the chips are passed through a tubular dryer, which reduces the moisture content of the wood fibers to the desired level.
MDF door manufacturing typically uses a single-stage or multi-stage tubular drying system. Multi-stage tubular dryers have a primary dryer and a second-stage tubular dryer separated by a cyclone collector or other discharge point. Heat in the tubular dryer is usually provided by natural gas, distillate oil, propane, or indirect heating.
Mixing stage
The wood fibers then enter the mixing area, but the order of the drying and mixing operations depends on which method is used to mix the fibers with the resin and other types of additives. The most common resin used when making medium-density fiberboard is urea-formaldehyde, but melamine resins, isocyanates, and phenolic resins are also used.
Some facilities will inject the resin formula into a short-retention mixer, although most plants inject the resin into a spray-pipe system. If the resin is injected into a separate mixer, the fibers are first dried and separated from the air stream using a fiber recovery cyclone before they are fed into the mixer. These wood fibers are then mixed with wax, resin, and other additives before they are fed into dry storage containers.
Suppression stage
The air then transports the resinized fibers from the storage bin into the forming machine. Here they are placed on a continuously moving screen system. This continuously formed mat needs to be pre-pressed before being loaded into the hot press.
After the pre-pressing step, the mat will undergo some pre-trimming. The trimmed material will be collected and sent back to the forming machine. The pre-pressed and trimmed slab will be sent to the hot press. The hot press will apply pressure and heat to activate the resin, thereby bonding all the wood fiber materials into one solid slab door.
In some cases, the slab may be pressed in a continuous hot press, while in other cases, the pre-pressed board may be cut into individual slabs using a flying saw. These slabs are then loaded into a batch-type multi-opening hot press. Domestic equipment usually uses hot oil or steam to heat the press platens.
Door skin stage
After pressing, the slabs are cooled, sanded and trimmed. They are then sawn to final size. Painting and lamination may also take place during this step. Finally, the finished MDF products are packaged for shipping and used to make interior doors.
Advantages of MDF Doors
The reason why MDF interior doors have been able to remain popular in the market for a long time is that they have many advantages over traditional interior doors.
- No warping
| Like wood, MDF will shrink and expand due to humidity and temperature fluctuations. However, unlike wood, MDF will not warp. This is thanks to the structure of the board, which allows it to move as a whole. Even with large temperature and humidity changes, wood damage will not be a problem. No more worrying about a warped wooden door that won’t fit into the door frame! Solid wood doors are extremely susceptible to heat and cold, and rapid fluctuations in humidity and temperature can have a negative impact on solid wood doors. Despite advances in technology and manufacturing, wooden doors will still experience a certain amount of shrinkage and expansion. |
- Smooth surface
| MDF boards consist of very fine grain, which means there is no noticeable grain. The result is a better, smoother surface, especially after painting. If your client wants to paint their door, it is recommended to use MDF doors instead of solid wood doors. |
- More customizable
| Due to the structure of MDF boards, they can be drilled and cut in a variety of ways without damage. This provides great flexibility in your door design. MDF door materials make them easily customizable, which explains why there are so many door styles using MDF to choose from. MDF doors are also available in larger sizes. For customers who need a large piece of wood without seams, MDF is often the best choice. |
- Better waterproofness
| Moisture is a common problem with solid wood doors. While wooden doors can be well protected with a good finish, if the surface is accidentally scratched this can make it susceptible to moisture, which can attract mold. Mold is very adaptable and only requires a small crack for a colony to grow. What’s special is that MDF doors can be designed to be moisture resistant. Homeowners who plan to install doors in bathrooms or other areas with high humidity should consider purchasing MDF boards that are specifically designed to be water resistant, as regular MDF boards can still be easily damaged when exposed to water. |
- More affordable
| With MDF doors, homeowners get the strength and longevity of a solid wood door at a lower price. While not all solid wood types are expensive, most are. Many of the most popular wood species, like walnut, cherry, and white oak, are quite expensive, while rarer species like mahogany and teak are extremely expensive. Three factors that influence pricing are beauty, durability, and availability. |
- Easier to supply
| Another benefit of MDF is that it’s easier to find woods like white oak or maple, especially for customers looking for specific sizes and styles. |
- Flame retardant
| There are also flame retardant MDF doors. While this type of MDF door is most commonly found in commercial buildings, it can also be used for fire protection in homes, especially in areas such as bedrooms and kitchens. |
- Easy to use
| Because MDF is made from a lumber byproduct, contractors can easily cut, groove, or drill holes in it using regular carpentry tools. MDF pieces can also be fastened together using a variety of screws or nails. Even pocket screws can be used. MDF pieces can also be bonded together using nearly any type of adhesive, including door construction adhesives, polyurethane glues, and wood glues. |
- Environmental protection
| Purchasing an MDF door is an environmentally friendly decision. MDF comes from recycled and reused wood waste that would otherwise end up in landfill or be incinerated. MDF makes better use of natural wood resources and makes the most of every tree. In fact, MDF utilizes almost 100% of every tree used to make the product, while solid wood only uses two-thirds of each tree. |
MDF interior doors vs solid wood doors
MDF and solid-core doors are two of the most popular types of wood doors. In this section, we will briefly compare and contrast the two. If we put aside the cultural and nostalgic attachment to solid wood doors, it is safe to conclude that MDF doors outperform solid wood doors across the board.
The outer skin of a solid-core door is usually made of molded composite or plywood. The interior uses a blend of wood fibers to make it feel similar to a solid wood door. Solid-core doors are considered more durable than hollow-core doors and provide better noise reduction and thermal insulation.
MDF doors are an engineered wood product that have become a more popular choice for interior doors in recent years. While both MDF and solid wood doors are durable and relatively affordable, only MDF doors are resistant to warping.
MDF doors are an option worth considering for customers looking for doors with excellent sound and thermal insulation properties. MDF doors have a smooth, beautiful surface that can be easily painted. MDF doors are also more environmentally friendly because they are made from leftover wood products and sustainable materials.
How much do MDF doors cost?
For contractors and their clients, there are many options when it comes to choosing a wood product for interior doors. If the buyer is on a budget, price can be a major factor. In this section, we’ll walk you through the prices of MDF doors and how they compare to other wood products:
MDF Doors
MDF doors typically cost hundreds of dollars, but some are very affordable. MDF doors can be fully solid, hollow core, or solid, and are available in a variety of door styles. They are more stable than solid wood doors because they are less affected by moisture and have a very smooth surface that makes them easy to paint. Although MDF doors typically have a flat and smooth appearance, other styles are available. Fully solid MDF doors are usually heavy.
Hollow Core Doors
Hollow core doors are one of the cheapest options, rarely costing more than a few hundred dollars. Hollow core doors consist of an outer skin or shell made of wood, vinyl, or MDF, with nothing inside. These doors are lightweight, can be installed quickly, and are fairly affordable. However, they are not very effective at blocking sound. Hollow core doors are a popular choice for closet doors, but are also commonly used in passageways and bathrooms. They come in a variety of door sizes and door styles.
Composite Doors
Composite doors are also reasonably priced, though they are often priced much higher than MDF and hollow-core doors. As the name implies, composite doors can be made from a mix of various materials, including wood, MDF, and plastic. Composite door prices vary from door to door, so customers should check prices before ordering. They generally require little maintenance, but be aware that some composite doors can be negatively affected by moisture.
Solid Wood Doors
Solid wood doors are similar in price to composite doors. They are made from a single piece of wood and come in a variety of door styles, from plain to highly decorative. Popular wood species for solid wood doors include poplar, maple, ash, walnut, and oak. Keep in mind that the more durable and exotic the wood species, the higher the price.
Solid Core Doors
Solid core doors are the most expensive option, and can cost thousands of dollars. Solid core doors can feature a wood pulp core covered with thin wood panels, vinyl, or MDF. Some aluminum and steel doors also feature solid cores. Solid core doors are lighter than solid wood doors, but heavier than hollow core doors. They are also fairly effective soundproofing materials. Solid core doors can be a good compromise for customers looking for something strong and durable that is lighter than metal or solid wood.
Oupanpan designs and manufactures a large number of architectural-grade interior wood doors. Our door products are carefully built to the highest industry standards, and we use high-quality materials, including structural composite wood cores and plastic laminate overlays or wood veneers for a beautiful finish.
We have years of experience in applying the latest building codes, safety regulations, and manufacturer specifications. If you are interested in learning more about our interior door products, including wood doors and door hardware, you are welcome to contact the Oupanpan team at any time through this website. Oupanpan is honored to communicate with you about all issues related to interior wood doors.