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CNC Wood Machining - Doors

  • Wood doors
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As seen generally in the furniture industry's evolving demands for enhanced design capabilities along with real world capability for implementation, the development of today's door manufacturing technology, in particular, has seen the same drive with a renewed quest for functional beauty and style along with the manufacturing technology able to provide it.

 

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machine

Overview

Outside door with side lights

There has been a steady rise over the years, especially in exterior use, for doors with glass openings, due to the trend of building smaller houses and the need for more sun to the interior rooms. Yet the market for interior doors has also evolved towards more and more sophisticated and intricate products – such as folding doors – pushing manufacturers to be increasingly flexible in their production and, as a consequence, requiring more sophisticated CNC solutions, which have become the core of today's agile producers. In addition to this, the choice of materials employed, being part of the door's most basic quality has increasingly become a concern due to the rising expense of raw materials and their reduced thickness, for example: natural veneers, such as exotic species of walnut, oak, cherry and beech, as well as melamine coatings, used to meet the increasing demand for sustainable alternative materials.

CMS' technology has moved well past the concern of simply supplying single parts. Today's CNC solutions provided by CMS encompasses complete work cell systems, capable of producing all the parts of a complete door, one after the other or in batches, ready to assemble, based upon production demand to the order, "just-in-time", with internal factory tracking information which can be laser engraved on concealed edges, production flows allowing for complex product mixes and multiple tooling families, with multiple thickness requirements, driven by barcode identified raw parts, verified to match the data required for their production, and automatically downloading all required machining processes.

CMS also has technology available for assembled doors, by which each customer's specified hardware elements may be machined into the door, based on the order, "just-in-time" in flow through or work cell fashion.

Moving
table CNC's

KARAT - batch/high volume stile & rail production

KARAT - batch/high volume stile & rail production

CMS' KARAT, moving table class, CNC machining center is perfectly adapted for batch or high volume stile and rail production for passage doors. Karat's, high feed speed processing, double table version with special CNC controlled setup fixtures is designed to make setup fast and accurate for each powerful clamping vice, with end referencing, easy load/unload work area for the operator and high level protection throughout the work cycle, along with KARAT's range of powerful working units, including single or multiple ATC's, 5-axis or revolvers, means that Karat can provide parts immediately ready to assemble for door production. This photo shows the table to the left ready to receive rail parts and that on the right stile parts.

Moving
gantry CNC's

AVANT - assembled doors, hardware, lights

AVANT - assembled doors, hardware, lights

AVANT, CMS' moving gantry class of CNC machining centers, is specially equipped for working assembled or slab door production and to carry out the trimming to size, edge profiling, machining of lights and any required hardware for each door. Avant's design makes it possible for it to be incorporated into a flow through line or work in a stand alone automated cell. Avant's CNC controlled covered roller flow through system brings each door to the working zone where it is initially referenced from the front or back, depending on reference point required, and then from the side. Between Avant's roller drive system, CNC controlled vacuum pods, which raise and lower to permit adjustment to the correct door length, and which are also adjusted for the door width, will hold each door securely in place. Pods may be easily excluded from use where door hardware or through passage openings will occur. In case of machining for lights, Avant's roller drive system raises to just below the door's underside and permits the discarded light opening material to gently lay onto the rollers and subsequently be driven out of the machining center, separate from the door, while the cycle still continues. Avant also comes equipped with a range of different working units, such as ATC, 5-axis or revolver, which mean that Avant can accomplish each required machining task its given. At the end of each work cycle, Avant executes a compressed air cleaning cycle to ensure the pod surfaces are clear of debris, while the scrap take-away belt constantly removes any waste material that falls from the work process.

Avant easily accepts information from barcode scanning, making it easily integrated into automated systems, or, simplifying the operator's work.

Machining assembled doors: hardware and edges

Machining assembled doors: hardware and edges

AVANT's CNC controlled pod system, makes it possible to raise the door above the infeed rollers, providing complete, unobstructed access for all the work that needs to take place. In the picture to the left, a heavy profiling tool is being used to bring the door to size, as well as finish the edge work, while in the picture to the right, Avant is shown machining a plate and lockset opening horizontally with a 4th axis double ended aggregate, beneath which the vacuum pod has been lowered, so that, when the pass through machining takes place from above, the pod will be clear of the machining zone.
 

Avant - flow through belt, hardware machining

Avant - flow through belt, hardware machining

AVANT also comes with a flow through belt variation for slab doors, in which it's possible to carry out edge processing requirements on both sides of the door at the same time, increasing throughput and flexibility. As seen in this picture the lockset can be machined, while on the other side Avant, with a unique CNC hinge machining unit, carries out all the special requirements needed for the hinges.
 

Close up of Avant's special CNC hinging unit

Close up of Avant's special CNC hinging unit

In this picture is seen CMS' special independently controlled CNC hinging unit. Depending upon production levels, it's possible to have more than one hinging unit working at the same time, as well as carrying out concurrent machining with a working head on the other side of the door, for the lockset or light opening machining. CMS' CNC controlled hinging unit works with prefinished doors, as well as unfinished doors, and first aligns the door to determines where the edge is, from the front or back end, providing for right and left-hand door versions, then the side, into which the hinge needs to be machined. The hinging unit makes sure that there is no blow out, by pre-cutting the exit path first, and drills for all required bore pattern holes, and the hinging unit can also be supplied with a square corner chisel device, if required. In addition, the hinging unit is adjusted by the program for the angle of the door edge, standard is +/- 3°, or straight up and down.

Pro Evolution
in-line CNC's

Pro Evolution - high speed, just-in-time, by the order

Pro Evolution - high speed, just-in-time, by the order

CMS' Pro Evolution, its dramatic new introduction for just-in-time, high volume production, for stile and rail, door and window components, is a state of the art scalable solution. Pro Evolution provides the technology, methodology and raw power to produce to each order, just-in-time, all the stile and rail parts required for each door, and can accept variations in length, width and thickness, even different profile families, if necessary, one part after the other. Pro Evolution's new CNC clamping technology means that each part is always held firmly and securely, never released, throughout the entire production cycle, resulting in the highest accuracy. In addition, Pro Evolution is designed to receive the information required for each part, or pieces to be derived from a single longer part, via barcode, which is analyzed, instructions generated and distributed to each subsequent machining area within Pro Evolution. Starting from the infeed, where the information is scanned, the part size is verified so that the actual part must correspond with the barcode label information, and ending with the outfeed, Pro Evolution manages flawlessly the high volume, just-in-time, to the order production its given; and Pro Evolution is scalable for even higher throughput levels, with its Pro Evolution 1, 2 and 3 versions.

Images

Curved door & side lights

Curved door & side lights

An example of a stile and rail arched door with side lights, though complex in design, not difficult with CMS technology

Stile & rail door - cathedral rails

Stile & rail door - cathedral rails

A beautiful stile and rail raised panel door with cathedral upper rails.

Mullion stile and rail door

Mullion stile and rail door

Stylish mullion stile and rail door

Double doors

Double doors

Double door, stile and rail with raised panels. The special handing requirements are no problem for CNC processing.

Arched Door with side lights

Arched Door with side lights

A stunning stile and rail arched door with intricate leaded glass side lights. CMS, through its glass division, also supplies the CNC cutting machinery for this work.

Slab commercial office door

Slab commercial office door

A simple, high quality Oak slab door

Videos

Wood Doors: Case History and Technology Overview

An overview and video case history of Audasso, high quality door manufacturer. The case history presents a wide range of manufacturing processes and doors styles including stile and rail production as well as assembled doors. The case history is followed by a presentation of CMS' broad range of CNC solutions for door manufacturers including flow through style, inline, and stand alone, AVANT and KARAT families of CNC machining centers, the wide range of CMS' working units including revolvers, ATC, 5-axis and combined groups, as well as close-ups on hardware machining, light cutouts, profiled edges and CMS' unique CNC controlled hinging unit.
 

Karat - stile & rail production, CNC setup holding fixtures

Presented in the video, Karat, in a double table version, has CNC controlled fixture setup for multiple parts. Production takes place in a nonstop cycle and prefinished parts have rabbets and tenons machined along with horizontal drilling for dowels.

Flow through door machining and CNC hinging unit

A closer look at CMS', pre-assembled door, flow through belt version, CNC machining center and its unique independently controlled CNC hinging unit, as well as the referencing system, providing for right or left-hand doors, including a range or hardware machining.

Pro Evolution - high volume, by the order stile and rail production

CMS' Pro Evolution is shown machining stile and rail parts for window frames, including the glass bead, in a demonstration equally applicable to stile and rail doors. Pro Evolution was designed by CMS to cover the range of needs for both door and window manufacturers, which are virtually identical, so that high production, by the order manufacturing, would be the result. The information is automatically downloaded to Pro Evolution via barcode and processed based upon the characteristics of each particular stile and rail and then distributed to the subsequent processing areas of Pro Evolution as the component moves through the process cycle. Each component is held securely throughout the cycle by Pro Evolution's patented CNC carriage clamping devices, which preserve the accuracy of each part while permitting complete machining of all required edges.

Files

Wood Doors Sector and Audasso Case Study
(click folder on the left to download)