Domestic Walnut Wood Grain Large Door

See: How to Build The Perfect 16 ft. Tall Walnut Door

Sing wood stave doors skins

Click the pictures to see our wood stave door skin gallery!


Our panels make doors!

Patented Sing Core solid wood stave door blanks feature the newest technology in the door industry for composite doors yielding the only eco-friendly, lightweight, fully insulated, high-strength doors with wood blanks of any size (up to 40 ft.) that can be guaranteed true flat and to stay flat for 50 years.


The secret to creating an incredibly stable wood stave door is what lays underneath the wood plank. At Sing Core, the True Flat Team is likely to laminate 1/8″ wood stave over top of AB Plywood. If stave is thicker, then it is suggested that you float the planks (by nailing them) to 3/8″ AB Plywood for the best results. Exterior doors featuring wood stave should have AB Plywood or Marine Plywood underneath. Of course, your door will only remain straight for 50 years, if you have Sing Core technology inside.

Large door versus regular-size door challenge (i.e., over 4 feet wide and over 8 feet in length):

Large doors are heavy, dimensionally unstable, require more strength due to the heavy weight, and are a challenge to manufacture, ship and install.  High-end jobs require precision and true flatness to please the customer.  A homeowner’s architect, general contractor and mill worker must solve the problem of warping doors.  The solution to the challenge is to use patented premium true flat Sing panels to make your doors.

Sing Core wood stave door planks are the only solid wood doors that will not warp, bend, twist or cup following installation.  This means no more continuous service calls for maintenance of big doors that cannot possibly stay straight due to the limitations of solid wood – or any other door core – that is subject to failure.  Sing panels have a patented honeycomb/torsion box interior which gives lightweight yet unsurpassed strength (pound-per-pound stronger than steel) and stability to any door, and allows Sing Core to provide a 50-year guarantee

Interior Doors:

Sing panels make amazing designer doors in any style.  With Sing panels, fragile doors such as French doors are made lightweight yet strong, not warping or breaking hinges, which will last for many decades.

Exterior Doors:

Sing panels make sturdy exterior doors in any style.  With Sing panels, exterior doors are lightweight and strong, even when oversized.  Our premium doors are guaranteed to stay true flat and not warp or twist for 50 years

Modular Oak Doors

When is a door not a door? When it fails to function as a door.

The problem is that all door core materials are either not high precision, too heavy or will move when exposed to moisture, humidity or change in temperature resulting in door failure.

Heavy solid metal or steel will not warp, bend or twist, but is not high precision due to welding (sing core tolerance is + or –  .006 inch!) and is often impractical due to the overweight issues causing excess strain on both the hardware and structure, causing continued maintenance issues.  The solution is our patented lightweight yet strong Sing core technology.

Big Oak Doors

Here’s an example of a pair of 10 x 12 big oak doors, 3-inches thick. These are made using solid oak wood stave (or planks) trimmed thin at 1/8-inch and applied to patented Sing Core engineered substrate.

10×12 ft 3″ thick warp-free 1/8″ oak 520 lbs

The face staves or planks are expertly applied and nearly seamless. If done any other way, these face staves will separate or crack due to movement of the surface area, but because Sing Core does not move, this surface area will remain in pristine condition thanks to inventor Peter Sing’s warp-free contribution to the large wooden door industry.

Close up example of oak wood stave (plank) lamination

The secret to making a big oak door, like this, look like a solid oak door is to use matching oak grain stiles and rails for framing. So instead of edge-banding on the panel sides, you see solid oak wood edges which gives this the impression of being a big solid oak wood door.

extreme close up of corner revealing solid oak stile and rail frame

Finishing a door blank:

There are two types of finish for door blanks:  paint grade and wood grain.  Paint grade includes such finishes as metal, MDF, marine plywood, etc.  Wood grain finish includes such finish as solid wood stave and thin veneer.


This massive walnut door is designed with our special process to appear like a door made with one huge piece of solid walnut.  Clocking in at a whopping 11.5 feet tall and more than four feet wide, the door weighs a mere 177 pounds, ensuring very little stress on your hardware and mounting points.  This will guarantee your door will stay straight, strong, and functional over the long haul.  SingCore is the home of the 50 year door!


Why Use Solid Wood Instead of Veneer?

solid wood composite door planks any size thickness true flatNever settle for substandard veneer doors again. Door engineers prefer to use inexpensive veneer as opposed to real solid wood facings because veneer is thought to be less likely to warp, bend or twist.  But thanks to the super-strength of patented Sing Core technology, you can use solid wood stave and wood blanks with confidence knowing that your door can be guaranteed true flat and will stay flat.

How can a solid wood-faced door stay true flat? As every woodworker knows, when using a solid wood surface, the grain will move according to moisture or temperature change causing the door to fail. When using our patented Sing Core as a substrate you can safely use solid wood because the solid torsion box/honeycomb patented material is continually keeping the wood grain straight and true.  Whereas traditional wood stave doors contain a much greater proportion of wood fiber content, thus have a high probability of warping than thin veneer due to the imbalance of moisture content on each face of the door, patented and patent pending Sing technology solves this problem by combining stiffeners with patented Sing core on the interior of our doors.  This Sing panel technology eliminates the troublesome movement of the door blank — warping is no longer a concern when wood stave is applied to patented Sing core.


In addition, solid wood is easy to work with, install (no need to hot press), repair and remodel.  That’s why professionals trust Sing Core’s years of expertise in helping to design the only wood stave doors (that look just like solid wood doors) that can stay straight and true for many decades while respectfully honoring the beauty and elegance of solid wood, which far outlasts easily-damaged veneers, yet can be sanded and repaired if necessary.

Celebrate your real wood!

solid wood stave door planks lightweight honeycomb guaranteed 50 yearsOur Eco-friendly lightweight, high strength alternative is the best   solution for combating the issues associated with weight and size,   especially large doors.  Only our patented Sing torsion box/foam   composite core combined with our years of experience provides   guaranteed solutions for oversize doors.

That’s why this technology is found everywhere, from beneath the sea   (US Navy) to outer space (NASA) and everywhere in-between.

Sing panels may be finished in almost any wood species, like   mahogany, redwood, teak wood, cherry wood, walnut wood, cedar   wood, Ipe wood, sapele wood, poplar wood, ebony wood, ash wood,   oak or any other hardwood or exotic wood types available.

This same wood blank composite technology is also a common solution for high-end projects like engineered hardwood flooring, shiplap, wood furniture, wood shelves, decking, shed doors or any other application demanding high precision and exemplary performance over time.



How is wood stave/veneer applied to Sing panels?

The highest quality, premium wood stave is generally applied directly to our patented Sing Core material.  Wood veneer uses a special process where we use super high quality, most often domestic, veneer cut from the same logs for best matching.  Veneer is then applied to an intermediary layer of MDF that sits on top of our Sing Core.  This combination of methods allows us to make make doors that are some of the most visually appealing on the market, yet are unexpectedly exceptionally dimensionally stable.  They are also some of the lightest weight doors on the market within their size range.  Because of this winning formula, we are the only company on the market that can manufacture large, oversized doors that appear like solid wood, yet come with our Signature 50 year Guarantee against breaking, skewing, warping, twisting, and cracking.  Depending on your budget, we will be able to provide you with the absolute best option for your needs.  We are always here to provide you with free consultation on the best option for your project.  All you need to do is call us!


Huge Pivot Door Mahogany Wood Veneer

Wood Stave vs. Wood Ply

Wood stave doors are among the most premium doors of all doors on the market.  Typically they are made with the highest quality hard woods, like Mahogany, Oak, Walnut, Maple, Alder, Cherry, and Teak.  Despite the many benefits, wood stave doors can be very costly to make, especially if you’re looking for a lightweight high strength solution for a warp-free guarantee for 50 years. Using Sing Core inside your wood stave door featuring wood planks from 1/8-inch to 1/4-inch will create more potential for warp due to the nature of natural wood grain.  This is the beauty of the more economical wood ply option for building your wood door. Wood ply is far less expensive and has alternating grain orientation which also helps to keep the door straight. Wood plywood is just like any other plywood except for its featuring a particular wood grain predominantly on the surface, and it offers far more strength and repairability over time than a less expensive wood veneer.

So, if you’re looking to attain similar visual results of a solid wood door at a fraction of a price you might consider having Sing Core inside your wood plywood door. Be certain to specify what type of natural wood plywood your want, if it is available, you can save thousands of dollars on your beautiful wood door. The most popular wood plywood features woods such as white oak plywood, maple plywood, oak plywood, mahogany plywood, walnut plywood, Douglas fir plywood, knotty pine plywood, and birch plywood just to name a few.


Note: the seam is tight but still slightly visible when joining two pieces of domestic plywood together to create a large panel.


The Domestic Difference

Let it be known that all of our products here at SingCore are 100% handmade in America.  We make everything by hand right here at our factory in sunny McCleary, WA.  Order now to see the difference!  Why settle for anything less than the best?

SingCore Signature Guarantee

The SingCore Guarantee is a testament to the quality of our doors.  We stand behind our craftsmanship because we know how well our doors hold up under rigorous use.  We guarantee them against cracking, breaking, twisting, skewing, and warping.  Our professional panels are guaranteed for 50 years.

How to vacuum-press (video) with Sing Core

How to Buy

To order Sing Large Door panels see our pricing page  and submit an order form either by email,, or print and fax it to: 360-495-4585. We’ll provide a quote within one to two business days. If you have questions, please contact us.

Easy Ordering

All we need to know is the length, width, thickness and your choice of door skins to make your  custom specialty panels to suit your exact needs. Getting a quote for your specialty product, is easy, thanks to our simple online order system.

Bulk Discounts

Fast turnaround: In you’re in a rush, only Sing Core can be custom made within 24 hours and is proudly manufactured for you in the USA.

Fast delivery: Any thickness and almost any length, less than 5 ft wide, can be made with in 48 hours if it is rush order.

SINGCORE Large Doors are easy to order. You may choose from our stock panels or order custom sized panels. Our price is based on the length, width, thickness, and quantity. Submit a Work Order by fax or email, and we will give you a quote within one business day. If you have a tight budget, give us a call, we might have an alternative solution tailored to your needs.

Applications -> Building Components -> Doors

The only 50 year warp-free guarantee and full structure warranty

Types/Styles of Doors -> Sliding Doors -> Pivot Door -> Flush Door -> French Door -> Carriage Door

Large / Oversize Doors -> Standard Doors -> Exterior Door -> Interior Door

Door Skin Types -> Wood -> Wood Stave -> Aluminum -> Metal -> Steel

Door Finishes -> Specialty Doors -> Soundproof -> Fiberglass -> Fire Retardant


 Other Skin Options:

1/8″ wood stave skin doors are in our most premium category. 
In our economy class products, we offer soft wood and hard wood plywood skins.  We also offer MDO, MDF, Formica, Masonite, and many other skins.  Click here for more information.

In our mid price category, we offer beautiful, hard wood and soft wood veneer skin doors.  Check them out on our wood veneer skin doors.