Manufacturing for the Cabinet Industry for over 34 Years
The Door Stop started making kitchen cabinet doors in 1980. At that time we only offered 4 styles and those were only available in Red Oak. Back then the majority of Cabinet Shops made their own doors and, because we only offered 4 door styles, we mostly supplied the replacement door market. In 1996 we registered the domain name CabinetDoors.Com and became the first manufacturer to launch a web site offering custom doors direct from the manufacturer to Home-Owners and Remodelers. Today we offer several hundred styles of doors and drawer fronts and ship to all 50 states. So for your cabinet door needs, CabinetDoors.Com is the leader in the industry supplying doors on the web longer than any other door supplier. We actually make the products for many of the other internet websites. We have become the leading supplier to the refacing industry across the country.
Over the next 34 years we invested in ever more modern manufacturing machinery that allow us to produce doors with tolerances that were unachievable a few years earlier. This new computerized manufacturing machinery allowed us to produce doors with sizes so exact that cabinet makers, with their tape measures, considered nearly perfect.
Our components are all cut with computerized machinery to tolerances measured in the thousandths of an inch and our doors, when completed, are guaranteed accurate to within 1/64 inch, or about 15-thousandths of an inch.
Because cabinet makers realized that offering this level of sizing accuracy would increase their business, more and more custom cabinet shops started buying their doors instead of making the doors themselves. This increased volume from the cabinet shops allowed us to actually increase our investment in automated machinery. The result has been our ability to manufacture doors with sizing accuracy that no cabinet maker can consistently produce. We were also able to introduce new door designs, and today we offer hundreds of different door styles in every domestic wood type available. In fact, considering all the optional door styles, wood types, panel designs, stile details, outside edges, cope & stick and mitered, arched and square, etc...the possible door permutations come to millions of possible different designs, and greatly increased the number of styles that could be offered.
This possibility of offering so many designs has convinced the vast majority of custom cabinet shops to buy their doors instead of making their own, and the most kitchen refacing shops are now buying the doors used in their refacing projects. Inset panel doors are now almost totally outsourced to dedicated manufacturing factories. Outsourcing the doors also frees up labor for other tasks and avoids the increasing cost of machinery needed to produce the product. Over the last decade, as door machinery has become computerized, machinery costs have increased dramatically. With the costs of producing superior quality doors in volume exceeding several million dollars, it no longer makes economic or business sense for a cabinet maker to even consider making his own doors.
CabinetDoors.Com is constantly adding new equipment and this year is no exception. Two new triple-head widebelt sanders have been added along with computerized coping machinery and computerized mitering equipment. We are also adding new Mitered Door sanding capability. Our investment in our factory and equipment exceeds ten-million dollars and is growing every year. This massive equipment expense pays for itself because we don't just supply one cabinet maker, we spread this expense over several hundred cabinet shops so our equipment expense per door (or per cabinet shop) is actually far less that that of any cabinet maker making doors only for his own use.
We believe that it requires the very best modern manufacturing machinery to consistently produce a superior product at serious volumes and our commitment is to continue to grow and invest into the future.
Today's most popular doors can be grouped into two major categories, and dozens of sub-categories. These two major categories are Cope & Stick and Mitered.
Cope & Stick doors can be recognized by the design of the doors frame. The Stiles (the left and right--vertical-- pieces of the frame) extend from the door's bottom to the top. The Rails (the horizontal pieces of the frame) extend from left to right and connect into the stiles.
Possibly the most recognizable Cope & Stick door is the Shaker Door. The Shakers had a design philosophy that still holds true today.
“Don’t make something unless it is both necessary and useful; but if it is both necessary and useful, don’t hesitate to make it beautiful.”
Following that philosophy, Shaker Doors consist of a simple square frame with an inset panel. The door has no inside or outside profile on the frame pieces and no grooves or profiling on the panel. A very simple, yet functional design that still lives on today.
Most popular Cope & Stick doors today go well beyond the simple Shaker style. Today's Cope & Stick doors can be built with any one of several hundred possible details on the inside and outside of the frame. They can have Inset Panels, be Glass Frames without panels, or have Raised Panels with dozens of Panel Profiles to select from.
Cope & Stick doors, sometimes referred to as traditional doors and 5-piece drawer fronts, can be manufactured in almost any wood type. CabinetDoors.Com offers a selection of dozens of woods certified by the Forest Stewardship Council (FSC) as being sustainably harvested.
Today's market consumes slightly more Cope & Stick doors than Mitered Doors, but the Mitered doors have been steadily gaining market share in the United States.
Today the possibilities in mitered doors is much greater than the Cope & Stick lines. The reason being that while we offer several dozen Cope & Stick Stile-cuts, we offer 86 Mitered Stile-cuts. When multiplying the 86 Stile Cuts with the different wood types, the list of Panel Cuts, and the Possible outside edges, you have over three-million possible Mitered Door design combinations.
This huge number of door design possibilities is one reason for the growth in the popularity of number of Mitered doors for sale.
Another reason for the growing popularity of Mitered Doors is the evolution in equipment used to machine the miter joint. Our machinery uses computer control to cut an exact 45-degree miter then actually machine the hidden mortise and tenon into the stiles and rails. This method produces a perfect miter with the tightest miter joint in the industry. The machined mortise and tenon eliminates the need for biscuits or dowels and provides a much larger surface area to produce a glue joint which is far stronger than other joining methods.
Our Mitered doors are available in all sustainably harvested Domestic woods and will be produced in under 10 days.
Over the past 10 years, we have manufactured and shipped several million doors into all 50 states, Canada, Mexico, and 17 other countries.