Hiding Edge Seams in a Laminate Door

Advice on how to built without seams where a door edge meets the face. January 25, 2013

We do a small amount of p-lam work for one particular client. Here's our process for creating door panels: we start with 3/4 shop birch, laminate the back with gator ply, laminate the four edges, and then laminate the face so that you see the phenolic lines on the side but not from the face.

Is there a technique or tool to use so that I can order pre-laminated panels and apply the laminate edge underneath the laminate face so I don't get the phenolic line on the face side?

Forum Responses
(Laminate and Solid Surfacing Forum)
From contributor J:
You could band them with matching PVC, then you would have no black lines.

From the original questioner:
The client doesn't like that look. Also, they prefer laminate edges.

From contributor M:
I think that's the standard process for full laminate doors. Certain glue pot edgebanders can apply and trim the laminate edges. If you want to save a step and materials just use melamine instead of plywood. It will probably make a flatter and more consistent door than your plywood. The only other way I know of is miter-folding the laminate, and done correctly it appears seamless.

From contributor S:
AWMAC standard for doors is to have the same laminate on both faces, otherwise you will end up with warping. Basically the two most used methods for laminate doors is cutting your core material, either ply or particle core, edging four sides, and then laminate faces. The second method which is used by most of the shops in our area is to get 4x8 sheets glued up, cut, and then run on the edgebander. This method is a lot faster.