Production line and factory setup overview
A small sheet-metal fabrication line producing residential and commercial steel door leaves with matched frames through sheet receiving, CNC shearing or blanking, punching, bending or frame roll forming, stiffener and lock preparation, spot/MIG welding, grinding, pretreatment, powder coating, core filling, hardware assembly, hanging, fit inspection and protective packing.
Recommended lowest-entry line configuration Start with two standard single-leaf sizes and one knock-down or welded frame family. Use a 4-6 mm CNC shear, 100-160 t press brake, 40-80 t punch, frame roll former only if volume justifies it, welding fixtures, compact phosphate/powder-coat booth and oven, assembly benches and a full opening/closing test frame. Fire-rated or security certification is excluded until tested.
Production process and implementation sequence
- Sheet and hardware receiving
- Blanking, shearing and punching
- Leaf pan bending and frame forming
- Stiffener, hinge and lock preparation
- Fixture-controlled welding and grinding
- Pretreatment, powder coating and curing
- Core, hardware and seal assembly
- Hanging, functional inspection and packing
Products, capacity and market fit
- Housing, shops, schools and warehouses require durable standard steel doors and replacement frames.
- Local fabrication permits site-specific wall thickness, handing and hardware.
- Two launch sizes keep dies, locks, hinges and finished inventory manageable.
- Door performance depends on the complete leaf-frame-hardware-coating assembly.
- Standard steel door set - Leaf/frame size, handing, skin and frame BMT, core, hinges, lockset, finish and clearances - Homes, shops and institutional buildings
- Replacement steel doorframe - Wall opening, throat, anchors, hinge/strike positions and coating - Renovation and contractor supply
Core production machinery and line specifications
| Machine / stage | Function / value | Production note |
|---|---|---|
| CNC shear and sheet handling | Produces accurate leaf/frame blanks | Launch sheet range |
| Press brake and tooling | Forms leaf pans and frame returns | 100-160 t entry |
| Punch press and lock/hinge dies | Makes repeatable hardware features | Two launch sizes |
| Frame roll former or dedicated brake tooling | Forms matched frame sections | Volume-based choice |
| Welding fixtures, spot and MIG welders | Controls assembly geometry | Leaf and frame jigs |
| Pretreatment, powder booth and oven | Provides durable finish | Ventilated compliant system |
| Assembly and functional test frame | Installs hardware and releases door sets | Full-cycle inspection |
Raw materials, utilities and factory requirements
- Cold-rolled or galvanized steel sheet by BMT and grade
- Stiffeners, approved cores, hinges, locks, seals and anchors
- Pretreatment chemicals, powder coating and masking
- Cartons, foam, corner guards, labels and pallets
- Three-phase power sized for press brake, welders and oven
- Compressed air and welding-fume extraction
- Ventilated chemical pretreatment and powder-recovery area
- LPG/diesel/electric curing source as selected
- Dry sheet, hardware and finished-door storage
Indicative low-entry investment and implementation plan
These planning ranges prioritize economical machinery, local labor and local civil works. Final pricing follows confirmed capacity, product specification, delivery terms and site conditions.
| Scope | Indicative range | Entry-plan note |
|---|---|---|
| Shear, press brake and punch | US$28k-75k | Flexible workshop basis |
| Welding fixtures and forming tooling | US$10k-30k | Two launch sizes |
| Pretreatment, powder booth and oven | US$18k-55k | Compact finishing scope |
| Assembly, test, freight and installation | US$12k-35k | Door-set acceptance |
| Indicative installed low-entry total | US$68k-195k | Building, generator and working stock excluded |
Detailed proposal and next step
The proposal contains the complete line flow, machinery scope, raw-material and utility requirements, implementation stages and indicative entry planning. Final configuration follows confirmed products, capacity, site and budget.