The most popular application for wooden doors is accentuated by their prevalence as interior doors. There are a number of reasons why it is common for wood doors to be used as interior doors, the number one reason is that as exterior doors, wood front doors are less stable due to the nature of wood grain to move resulting in warped doors. But not anymore, thanks to warp-free wooden doors by Sing Core.
The two biggest problems with big wooden doors are the (1) heavy weight and (2) tendency of wood to move due to changes in the environment leading to warped doors. Inventor Peter Sing has introduced to and made available his patented and patent-pending warp-free technologies to all industries. The industry which his technological breakthroughs have had the most impact is on the door and window industry.
Known the world over for his contribution to his warp-free wood and the strongest metal in the world which are both lightweight and Eco-friendly, the biggest and best door companies, millworks, and high end custom wooden door manufacturers are seeking out Sing’s emerging lightweight high strength core solutions to enable them to build doors that were either impractical or impossible to build without inviting a host of complications and problems over time.
Door engineers and contractors who would pass on even considering building large wooden doors would pass on that part of the project due to the exposure of not being able to offer a warranty on a large wooden door that would warp not long after installation.
Sing’s core helps empower purveyors of doors to boldly and confidently embrace the idea of providing large wood doors which Sing backs up with his
50-Year Warp-free Wooden Door Guarantee
This is not a misprint or typographical error. Peter Sing personally guarantees each large oversized wooden door that he helps his clients to build to remain warp-free for 50 years. That is to say that if your door has Sing Core inside, it will not warp, bend, twist, or otherwise fail (including lamination) for a full 50 years.
This is a guarantee which is unheard of amidst the door industry, as most wooden doors are not covered by any guarantee, and for those that are, the standard is 1 year and could include a limited warranty of up to 10 years. There is only one way to build a lightweight large wooden door that will not warp, and to do so you must have Sing Core inside.
How to Build Warp-free Wooden Doors
The secret behind Sing’s ability to build a warp-free door is not as easy as it sounds, as he has a team of warp-free wooden door engineers who he refers to as his True Flat Team which reviews every door, its size and active components such as hardware and surface material, as well as its location within the project or structure, and on the planet earth. The True Flat Team helps to design the perfect substructure to keep the door from warping, so every wooden door is a one-off individual work of art.
1. Hybrid Solid Core
Basically, Sing’s patented hybrid solid core includes a torsion box grid, where the grid size is relatively small, two to three inches, which is constructed of vertical grain wood fiber (many times stronger than standard horizontal grain). Each void of the torsion box is filled with a rigid (recycled) foam insert, and this reinforced grid structure is cold-pressed between two stress skins using formaldehyde-free adhesive. This is Sing’s base material, which is the basis of the core used within his strongest metal in the world.
2. Anti-wood-warp Technologies
Depending on the size of the wooden door, the wood species (and its thickness) hosted on the wood door’s exterior, the application, hardware, and location of the door, additional anti-warp and strengthening material may need to be added to the warp-free substrate to compensate for the additional concerns and challenges. Note that types of door hardware, such as side hinge, pivot hinge, or sliding door hardware, all have different inner configurations, specially designed for each application.
3. Solid Wood Doors
For that “looks like solid wood” effect for which Sing is renowned, solid wood edges matching the natural wood grain featured as the door’s surface material are added to give the appearance of solid wood doors when finished. You can see why doors built with the solid wood edges are featured at the top of the World Trade Center.
4. Apply Surface Natural Wood Grain Material
Sing’s factory has a unique expertise in the area of applying different surface materials to his warp-free substrate though since he supplies his patented products to door companies and millworks, more than half of them ship without door skins, and these are applied at the door company’s factory or in the millwork’s shop. Some will feature solid wood stave planks, others will host various wood veneers.
As is the rule, Sing’s factory does not finish the doors, apply hardware, or pre-hang the doors. This is all done by the companies that make Sing’s door look so magnificent in the field.
What to Expect from Sing’s Wooden Doors
When your wooden door with Sing Core inside is completed and installed you can expect to enjoy all the benefits of owning such a door.
1. Eco-friendly
2. Increased sustainability
3. lightweight
4. High strength
5. Dimensional stability
6. Warp-free technology
7. Sound dampening
8. Increased climate control
9. Save on maintenance cost
10. 50-year no-fail guarantee
You will agree, just as all the other door companies now know,
Sing wooden doors make the best wooden doors in the United States and around the world. No other Eco-friendly lightweight wooden door core is stronger. Weighing in at a fraction of the weight of solid wood door core, patented Sing Core is stronger than steel pound for pound (660 PSI). This is the only way to make a large oversized wooden door that can be guaranteed not to warp, bend twist or otherwise fail for 50 years.
Wood Stave
American Plywood
Solid Veneer
Black Oak Doors
Cedar Doors
Sing Core Wooden Doors
Each professional Sing wooden door can be guaranteed to remain warp-free for 50 years, including a full structure warranty. This is why Sing Core wood doors are making such a huge impact on the door industry across the USA and abroad.
Any type or style of wood door can be made with Sing Core inside, such as exterior wooden doors, wooden barn doors, interior wood doors, wooden sliding patio doors, wood sliding room dividers, wooden French doors, wood stile and rail doors, just to name a few.
Patented Eco-friendly wooden doors with Sing Core inside are proudly made in the USA, using sustainable manufacturing methods using less energy, with responsible use of recycled and renewable resources, including natural wood fiber, producing little or no waste or loss of energy, leaving a negligible carbon footprint.
There is just no other way to make 20 ft. tall wooden doors that will not warp. Wood is a very difficult resource to use for anything over 7 ft. tall because of its tendency to move, especially in exterior wood doors. For instance a wood door that faces the elements on one side and the structure’s interior on the other is going to warp. That’s why no door company guarantees warp resistance of a wooden door for more than one year, that is, unless it has patented Sing Core inside.
So, how can you get wood doors with Sing Core inside? It’s easy, just go to your favorite architect, door manufacturer, mill work, or custom door company, and tell them what size door you want and be sure to ask for, “Sing Core inside.” We cannot sell or ship Sing Core doors directly to consumers or do it yourselfers, as we are the manufacturer supplying Sing Core door core only to door manufacturers and builders of custom doors.
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
Choose any available type of wood for your wooden doors with Sing Core inside, such as,
Wood Stave vs. Wood Ply
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 1/2-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 reparability 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.
Large Wooden Doors
Large oversized wooden doors are the greatest hurdle facing architects and designers, because though there is little more impressive than a huge wooden door to catch your attention, so the bigger the better, but then there’s the issue with warping, which is a constant struggle for the owner to secure regular maintenance of such a beautiful wood door, likely at least seasonally.
Thanks to having Sing Core inside, you will never have to worry about warping wood doors again. While they are built to last for centuries, each professionally guaranteed Sing wooden door can be non-warping and include a full structure warranty for 50 years. No other Eco-friendly, lightweight, high strength wood door can have such a guarantee in the world.
And what if you’re looking to build a large door out of a material other than a natural wood grain? No problem, your doors could be made out of any available flat building material, such as aluminum doors, cement, concrete, fiberglass (FRP), glass, HPL, Kevlar, LVL, MDF, steel (cold rolled steel, steel diamond plate, galvanized steel, hot rolled steel, etc.) as well as the only unbreakable mirror doors, just to name a few.
Wooden Door Gallery
Maple Doors
Mahogany Door
Oak Doors
Walnut Doors
Sing Core Wooden Doors
Each professional Sing wooden door can be guaranteed to remain warp-free for 50 years, including a full structure warranty. This is why Sing Core wood doors are making such a huge impact on the door industry across the USA and abroad.
Any type or style of wood door can be made with Sing Core inside, such as exterior wooden doors, wooden barn doors, interior wood doors, wooden sliding patio doors, wood sliding room dividers, wooden French doors, wood stile and rail doors, just to name a few.
Patented Eco-friendly wooden doors with Sing Core inside are proudly made in the USA, using sustainable manufacturing methods using less energy, with responsible use of recycled and renewable resources, including natural wood fiber, producing little or no waste or loss of energy, leaving a negligible carbon footprint.
There is just no other way to make 20 ft. tall wooden doors that will not warp. Wood is a very difficult resource to use for anything over 7 ft. tall because of its tendency to move, especially in exterior wood doors. For instance a wood door that faces the elements on one side and the structure’s interior on the other is going to warp. That’s why no door company guarantees warp resistance of a wooden door for more than one year, that is, unless it has patented Sing Core inside.
So, how can you get wood doors with Sing Core inside? It’s easy, just go to your favorite architect, door manufacturer, mill work, or custom door company, and tell them what size door you want and be sure to ask for, “Sing Core inside.” We cannot sell or ship Sing Core doors directly to consumers or do it yourselfers, as we are the manufacturer supplying Sing Core door core only to door manufacturers and builders of custom doors.
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
Choose any available type of wood for your wooden doors with Sing Core inside, such as,
Wood Stave vs. Wood Ply
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 1/2-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 reparability 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.
Large Wooden Doors
Large oversized wooden doors are the greatest hurdle facing architects and designers, because though there is little more impressive than a huge wooden door to catch your attention, so the bigger the better, but then there’s the issue with warping, which is a constant struggle for the owner to secure regular maintenance of such a beautiful wood door, likely at least seasonally.
Thanks to having Sing Core inside, you will never have to worry about warping wood doors again. While they are built to last for centuries, each professionally guaranteed Sing wooden door can be non-warping and include a full structure warranty for 50 years. No other Eco-friendly, lightweight, high strength wood door can have such a guarantee in the world.
And what if you’re looking to build a large door out of a material other than a natural wood grain? No problem, your doors could be made out of any available flat building material, such as aluminum doors, cement, concrete, fiberglass (FRP), glass, HPL, Kevlar, LVL, MDF, steel (cold rolled steel, steel diamond plate, galvanized steel, hot rolled steel, etc.) as well as the only unbreakable mirror doors, just to name a few.
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.
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 professional 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 professional doors are guaranteed to stay true flat and not warp or twist for 50 years
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.
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, Masonite, marine plywood, etc. Wood grain finish includes such finish as solid wood stave and thin veneer.
Why Use Solid Wood Instead of Veneer?
Never 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 wood stave has more wood fiber giving it more of a chance to warp than thin veneer due to the unbalance of the both side of the door moisture contents, patented Sing technology solves this problem by combining stiffing skin on both side of our patented Sing core. This Sing panel technology eliminates the troublesome movement of the door blank — warping is no longer a concern when wood stave is combined with 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!
Our 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 added to Sing panels?
Wood stave is added directly to the metal or wood skin our patented Sing cores. Wood veneer is added to an 1/8-inch mdf attached to the metal skin. Call us for a free consultation on the best option for your project.
All we need to know is the length, width, thickness and what you desire on the exterior, and your custom specialty panels are made to order. Getting a quote for your specialty product, is easy, thanks to our simple online order system.
Bulk Discounts
If you’re looking for a bargain price, remember, the more you order, the less expensive your total order will be per piece. Quantity and wholesale inquiries are encouraged. Feel free to contact us for more information. Click here for Closeout specials.
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.
