Membrane Pressed Components Improve Style and Durability of Closet Systems

ATLANTA, GA–Whether finished in a rich woodgrain or a simple white, closet components today must offer the quality appearance of solid wood. "People want their closets to look like their bedrooms and their pantries to look like their kitchens," explains Dennis Rose, president of SpaceMakers Closet Interiors, an Atlanta, GA-based manufacturer that specializes in creative storage solutions. "Where white or the occasional almond melamine system was once the norm, today's customers demand the look and feel of fine furniture in their closets."

"Double-faced melamine board is the workhorse material of the closet industry," says Rose, "but it is unsuitable for three-dimensional millwork associated with solid wood components such as raised panel doors, profiled drawer fascias, profiled cabinet tops and trim. We wanted to offer our customers and designers the look and feel of solid wood, but with increased durability, improved affordability, and enhanced functionality," explains Rose. "That's why we began offering CNC-routed wood components that are membrane pressed with a rigid thermofoil or 'RTF' from American Renolit."

In addition to simulating the woodgrain patterns of solid wood, the film can conform to virtually any three-dimensional shape routed into MDF substrates, from compound curves and intricate profiles to rounded corners and deep recesses, and do so with no visible seams, simulating everything about solid wood with convincing realism. The process imparts components with the stylish, three-dimensional appearance needed to stand out—as well as the durability needed to keep looking new and minimize callbacks.

Three-dimensional surfacing simulates solid wood

SpaceMakers fabricates components of MDF board that is CNC routed to produce raised panels, edge profiles and other decorative effects. Routed substrates are coated with adhesive and placed on a membrane-pressing table—with the rigid thermofoil suspended above—then slid into a chamber that heats the film and creates a vacuum, drawing the film tightly onto the part, as a flexible membrane presses the film from above onto all top and side surfaces of the substrate. Exceptional formability enables the film to reproduce virtually any shape including sweeping curves, fine details and undercut edges, while maintaining uniform wall thickness with minimal thin-out.

According to Rose, "The process eliminates T-moldings, edge banding and other labor intensive edge treatments that typically produce sharp corners, hard edges, and unsightly seams where separations can occur and dirt can collect, while simulating solid wood realistically, at a fraction of its cost."

Coordinated matches with melamine boards allow mixing, matching of components

"Until recently, matching melamine boards with rigid thermofoils presented a challenge for closet manufacturers. Clients would see a membrane pressed door sample they liked, but it wouldn't match the cabinetry," says Rose, "But American Renolit worked with Georgia Pacific and our other melamine suppliers to match all of the melamine colors and woodgrain patterns we offer, allowing us to mix and match melamine boards and membrane pressed components with confidence," he adds.

Quick turnaround allows customization, increased business

Family-owned and operated, SpaceMakers has established a retail marketplace within a 100-mile radius of Atlanta, and an expanding dealer network east of the Mississippi. Although the company offers storage solutions for all areas of the home—pantries, home offices, media centers, garages, etc.—its primary storage solution is a "closet-in-a-box," whereby shelves, drawers, doors, closet rods, toe kicks, and all other components of an order are custom fabricated in Atlanta, packed in boxes, and shipped to the site ready for installation.

To minimize lead times, the company stocks numerous components at its 30,000 sq-ft manufacturing facility in Marietta, GA. However, the quick turnaround and short run capability of membrane pressing affords the company enhanced flexibility in terms of customization.

"We custom manufacture all of our membrane pressed doors to allow our designers more latitude," explains Rose. "Currently, about 75 percent of the doors we sell are membrane pressed, and 90 percent of those have a woodgrain finish," he adds. Renolit woodgrains closely resemble the finish and grain patterns of premium, quarter-sawn hardwood (not shaved veneers). "Dark woods like mahogany and cherry are very popular right now and the more detail the better," he adds.

"Adding membrane pressed components to our product line has allowed us to offer organizing solutions to fit most budgets and tastes," says Rose, "and the impact on our business has been tremendous."