The Materials and Processes that go into Fiberglass Front Doors

Fiberglass front doors are deeply misunderstood. They tend to get the reputation of being the ‘budget option’, especially when compared with wood front doors because of the clear difference in price. People think that since wood front doors are more expensive, this means they are just the superior front door. This is a prime example of the Veblen Effect - consumers purchasing higher priced goods when similar, and sometimes even superior options are available at a better price.

This is not to take away from wood doors in any way - high quality wood doors have a timeless aesthetic and age beautifully over a lifetime. The point here is that a quality fiberglass door will meet the requirements for most consumers on a budget, appearance, longevity and energy savings basis. We recently wrote about why fiberglass doors are a smart investment for homes, and you can give it a read.

As always, the devil is in the details. Let’s answer some basic but essential questions - what are fiberglass doors, and how are they made?

How Are Fiberglass Doors Made?

Whereas wood doors are typically solid wood through and through, there are several layers of materials that make up a fiberglass door. Let’s break down the different layers of a fiberglass door below:

• The Center: At the core of a fiberglass door is Polyurethane foam. This foam is incredibly dense and acts as the foundation of the door. While lightweight, it is also an excellent insulator. This foam core is what makes fiberglass doors incredibly energy efficient.
• Reinforcement layers: High quality fiberglass doors (like the ones at Knockety) will have internal support ‘beams’ through and around the edges of the door. This additional support ensures the integrity and longevity of your fiberglass door.
• The Skin: The very outer layer of a fiberglass door. The skin is where fiberglass doors get their name. The outermost layer is crafted from a fiberglass - a mix of very fine glass and plastic fused together to create a smooth, durable finish. At Knockety, this outer fiberglass skin is treated with a gel coating to further protect against the elements.

Think of it like the layers of earth - the outer skin is like the earth’s crust, reinforcement beams at the earth’s mantle, and the polyurethane foam core is, well…the earth’s core.

These multiple layers are bonded by a cohesive agent, and again, just like the earth's layers- pressure and heat. A specialized adhesive is first applied to either side of the core, support beams and fiberglass skin. After The adhesive is applied, the piece is set in a high-pressure press where it is pressed with immense force andheat. The heat helps activate the adhesive and curing process. After removing from the press, the finished piece is left to set at room temperature.

Varying Degrees of Quality

Now that we’ve covered the basic construction of a fiberglass door, it’s important to note that there are varying degrees of quality within this manufacturing process i.e. not all fiberglass doors are built the same. The global fiberglass front door market is massive, growing at a rate of 9.1% and is projected to reach $33.0 billion by 2032.

Instead of using a dense polyurethane core, a cheaply built fiberglass door will use a lightweight material with inferior home insulation qualities. Additionally, this core may be semi-hollow or even filled with cheap filler material. They more than likely will use absolutely zero internal support beams and weak bonding adhesive. The worst part will be the fiberglass skin - manufactured from low-grade fiberglass that is thin and prone to cracking & denting. Whereas Knockety doors are guaranteed to last a lifetime, you’d be lucky to get 5 years out of a cheaply built fiberglass door before the exterior is completely destroyed.

These cheaply-manufactured doors are likely assembled in foreign countries with cheap labor and little regard for quality control.

The Knockety Promise

At Knockety, we often say our fiberglass doors are “so good, you’ll think it’s wood”. This isn’t just a saying - a majority of people who shop our wood-grain fiberglass doors without first reading their description think they’re looking at a wood door. This is just another testament to the quality and care put into each of our products.

Every single door that leaves Knockety’s warehouse in Houston, Texas is custom-built by you and hand-crafted from the highest quality materials available. Cutting corners is not part of our mantra, and our lifetime guarantee means we put our money where our mouth is.

By the end of reading this, you probably know way more about fiberglass doors than you’ve ever expected to. But hey, we’re passionate about doors!

We’re so passionate about this because we know that holding high standards for materials and manufacturing processes means that we can deliver a beautiful addition to your home at an affordable price. Knockety sells more than doors, we sell the entrance to your home - a responsibility that we do not take lightly. When you shop with Knockety, you support a family-run, made in America business with an absolute obsession with quality. We believe that means something.

We would love for you to join the thousands of homeowners across America who have built the fiberglass door of their dreams with Knockety. If you have any questions for us, please don’t hesitate to reach out to 713-400-6616 or speak with our design expert, Karla, via our website’s direct chat.