Ian Sage No Comments

Overcoming the Challenges of Custom Shaped Doors

Doors are not just functional elements in our homes and buildings; they are also essential design features that add character and aesthetic appeal. As architectural styles evolve and become more intricate, the demand for uniquely shaped doors has increased. However, crafting such doors presents a multitude of challenges for manufacturers. In this article, we will explore the difficulties of making shaped doors and how Sing Core can overcome these challenges.

Complex Shapes and Structural Integrity

One of the primary challenges in creating shaped doors is maintaining structural integrity while accommodating intricate designs. Traditional door materials such as solid wood or fiberglass often struggle to retain their shape and stability when subjected to unusual configurations. As a result, manufacturers face limitations in terms of design possibilities.

Sing Core, on the other hand, does no have these limitations. Composed of a lightweight yet incredibly strong honeycomb core, Sing Core has remarkable stability, even in complex shapes. Its unique construction incorporates a torsion box grid structure that ensures optimal strength, rigidity, and dimensional stability. This characteristic allows for the creation of doors with elaborate curves, arches, and other non-standard shapes.

Weight and Handling Issues

Another significant challenge in crafting shaped doors lies in their weight and the subsequent handling difficulties. Traditional materials used for door construction, such as solid wood or metal, can be heavy and unwieldy. This poses challenges during installation, transportation, and everyday use.

Sing Core panels address this issue by being exceptionally lightweight while maintaining their structural integrity. By utilizing a combination of advanced composite materials and a honeycomb grid core, Sing Core achieves an impressive strength-to-weight ratio. As a result, shaped doors made with Sing Core are significantly lighter than their traditional counterparts, making them easier to handle and reducing strain during installation.

Warping and Moisture Resistance

Traditional doors, especially those made of solid wood, are prone to warping and distortion when exposed to fluctuations in temperature and humidity. This is a persistent challenge for shaped doors, as the irregular surfaces and edges increase the potential for warping.

Sing Core panels, however, are guaranteed to be warp-free. Their high quality design and strong core eliminates the risk of warping and distortion. The honeycomb core of Sing Core also plays a vital role in maintaining dimensional stability over time. This ensures that shaped doors retain their intended form, even in challenging environmental conditions. In addition, all Sing Core panels come with a 50 Year Warp-Free and Structural Guarantee, so you can trust our panels to hold strong for many years to come.

Precision and Customization

Crafting shaped doors requires precise measurements, intricate detailing, and customization to meet specific design requirements. Traditional manufacturing methods often struggle to achieve the necessary precision, leading to inconsistencies and compromises in the final product.

Sing Core panels can be completely customized and are made with the necessary precision to meet the unique specifications of any design. This level of customization allows for the creation of truly one-of-a-kind shaped doors that fulfill the vision of architects, designers, and homeowners.

Conclusion

The challenges of creating shaped doors are significant, but with Sing Core, the industry has found a game-changing solution. By combining remarkable strength, lightweight construction, warp resistance, and precise customization capabilities, Sing Core panels enable the production of stunning shaped doors that were once thought to be impractical or unattainable. As architectural designs continue to push boundaries, Sing Core proves to be an invaluable asset in meeting the demands of modern construction and design, revolutionizing the industry in the process.

Sam Snyder No Comments

Large Sliding Doors

If you’re looking for the best large sliding door, you’ve come to the right place. Sing Core specializes in creating the ultimate sliding door experience. We manufacture the only door substrate that you can use to create the most extraordinary doors in the world.

The above picture is a demonstration of Sing Core’s strength.  Two 8’x9′ oak doors (approx. 800 lbs.) laying on top of two 7’x8′ curved doors.  The curved doors had no visible movement due to the high strength of Sing Core. As you can see, the eye plate is so small but can support such a large door panel.

 

These three curved panels measure 7’x8′ and are built to the highest precision and strength to last a lifetime.

 

Here is another example of a curved door with a smaller radius built with the exact same expertise.

 

Sliding Doors
The deal with sliding doors is that you want your sliding doors to remain straight and true throughout their service life. Architects, designers and end users face the issues associated with sliding doors, but rest easy knowing your sliding door has Sing Core inside.

Problems with Sliding Doors
The first problem with sliding doors is that they tend to move (warp, bend, twist or cup) compromising the doors’ performance. Especially in the case of sliding doors because they hang parallel to a wall (like sliding barn doors), next to another door (such as double sliding doors) or within a wall (like sliding pocket doors). If the door does not stay straight, it can wreck either the sliding doors or the surfaces they slide against, or both.

One way to overcome the warpage issue is to utilize stronger materials which tends to greatly increase the weight. The downside is that increasing the doors’ weight creates another set of challenge. For example, heavier doors require heavy duty hinges to support the doors. Heavier doors also require more labor for handling, installation, and any servicing it may require.

 

As you can see, this massive door is 8’x9′ and remains perfectly straight.  So straight, in fact, that it is perfectly freestanding on end!  If there was even the slightest amount of warpage, then this door would topple over.

 

Sliding Door Design Problems Solved
Architects and engineers are constantly perplexed with the problems associated with sliding doors, fortunately an Eco-friendly composite solution made in the USA, helps to solve the problems associated with faulty sliding door design. Patented Sing Core, along with their true flat door team, can help to create sliding doors that will remain straight and true far beyond the service life of any other sliding doors. By working with Sing Core’s design staff a combination of Sing Core and patent-pending sliding door stiffening solutions can create perfect sliding doors that are lightweight, high strength and can be guaranteed not to warp, bend, twist, cup or otherwise fail for 50 years.

These oak doors are manufactured with the highest precision.  As you can see, there is no gap between the two oak doors.  If they were slightly warped, or a little uneven, there would be a gap showing, possibly more.

The Perfect Large Sliding Doors
The best custom door manufacturers and millworks who offer long warranties on their large doors have a secret inside each one of their high end professional sliding doors: Sing Core inside. A properly designed and built large sliding door with patented professional Sing Core inside can be guaranteed not to warp, bend, twist or otherwise fail for 50 years.

Ivan Grantham No Comments

SingCore Curved Door — Custom Oversized Warp-Free Curved Door Panels

SingCore Curved Door

Bring your architectural vision full circle with the SingCore Curved Door — the only custom curved door system engineered to combine lightweight construction, warp-free performance, and a 50-year structural guarantee. Built for the world’s most ambitious architectural spaces, it delivers unmatched precision and long-term reliability at any size or radius.
Veneered curved door in hospital

 

The Ultimate Warp-Free Custom Curved Door

Bring your design vision full circle with the SingCore Curved Door — the only lightweight, warp-free curved door system backed by a 50-year structural guarantee. Whether for a luxury residence, commercial lobby, or museum installation, SingCore’s patented torsion-box core makes it possible to achieve any radius, size, or finish with unmatched strength and stability.

Painted Curved door with severe radius

Why Architects and Builders Choose SingCore

  • Warp-Free for 50 Years – Our patented core eliminates the twisting and distortion that affect traditional curved doors over time.

  • Lightweight, Strong, and Rigid – Up to 80 % lighter than solid wood or metal while maintaining exceptional structural performance.

  • Custom Radius Options – Built to your exact curve or arc specifications — concave or convex.

  • Compatible with Any Skin – Choose veneer, paint-grade MDF, marine plywood, HPL, metal, or other specialty materials.

  • Sustainable and Eco-Friendly – Made in the USA using renewable materials and minimal adhesives.

 

Painted curved door in residence

Curved Door Installed (Photo courtesy of Wirth Woodworking)

Custom Curved Doors for Specialty Architectural Applications

SingCore curved doors are engineered for architectural and high-performance environments where precision and reliability are essential. Each door is manufactured to exact specifications — radius, thickness, size, and finish — ensuring perfect integration with complex design elements and demanding installations.

Typical applications include:

  • Curved pivot doors

  • Curved sliding doors

  • Arched entryways

  • Radius wall systems and structural feature walls

  • Specialty architectural enclosures

Engineering Excellence Inside Every Panel

At the heart of every SingCore curved door is our patented torsion-box honeycomb core, providing a superior strength-to-weight ratio and warp resistance unmatched by traditional construction methods.
Unlike foam or solid cores that can swell, split, or distort under environmental stress, SingCore maintains precise curvature and structural integrity for decades — even in large or complex configurations.

Technical Highlights:

  • Custom-engineered thickness and radius to meet your design requirements

  • Exceptionally lightweight while maintaining structural rigidity

  • Compatible with standard or custom hardware systems

  • Fabricated for both interior and exterior environments

    Frequently Asked Questions

    What is the maximum size for a SingCore curved door?
    There are no fixed limitations — each panel is custom-engineered to your specifications.

    Can you build both concave and convex doors?
    Yes. Our process accommodates any radius curvature, including compound shapes.

    Can I apply my own veneer or finish?
    Yes. A hot-press-ready option allows you to apply veneer or laminate locally.

    Do you build exterior-grade curved doors?
    Yes. Exterior versions are fabricated with marine-grade materials and weather-resistant bonding systems.

    How do I request pricing?
    Provide your dimensions, thickness, radius, and skin preference to receive a custom quote.