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How is Laminate Flooring Made?

How is Laminate Flooring Made?

Laminate has remained one of the most popular types of flooring in the home for decades. Improvements in their construction have led to more realistic designs and enhanced durability. 

If you’re considering investing in a laminate floor, you may find it useful to understand exactly how it is made. In this brief guide, our flooring experts reveal what goes into the construction of laminate flooring to give you a better idea of what to expect.

How is laminate flooring made?

Laminate is a type of synthetic wood flooring made up of four different layers. At its centre lies a tough HDF core, providing the floor with stability and excellent durability.

How laminate flooring is made

The Way in which laminate is produced has changed dramatically over the years. This has led to a massive improvement in the styles and quality of the floors available. Today’s laminate floors are created by fusing the layers together in a single press procedure. This is done using Direct Pressure Laminate (DPL) at a high temperature of around 150 Degrees Celsius. 

What are the different laminate flooring layers? 

Each of the four layers used to construct laminate flooring plays an important role in its design. Below you’ll discover a brief rundown of what each layer is and what it is used for. 

The backer balancing layer

At the very bottom of laminate flooring, you’ll find the backer balancing layer. This is what provides the floor with its stability, giving it a straight base. Occasionally you will find a built-in underlay beneath the backing layer, but most laminates come with a backer balancing layer only. 

High Density Fibreboard (HDF) core

At the core of the floor is a high-density fibreboard layer. To create the core, wood fibres are combined with additives such as waxes and resins. This provides fantastic durability and strength. They are pressed tightly together using very high pressure to form a plank. 

Decorative paper layer

Above the HDF core, a decorative paper layer is added. This is what gives the floor its realistic wood or stone effect. Over the years, manufacturers have managed to produce hyper-realistic decorative paper layers, making the floors look almost indistinguishable from the real thing. 

Wear layer

At the very top of the planks, you’ll find a tough wear layer added to the laminate. This is basically a coating of aluminium oxide, giving it a beautiful shine while keeping it well protected against scratches, stains, and UV damage. 

The wear layer added to the floor will impact its AC rating. It is also available in a wide range of effects and finishes. 

Embossment 

Once the laminate planks have been created, the final step is to emboss the surface. This is done on most laminate floors to produce a more textured surface. The texture will typically follow the pattern featured on the decorative paper layer, adding to its realistic look. 

Cutting the planks to size

After the planks have been embossed, the cutting process can begin. The wood will be cut into planks, typically ranging from 200mm to 1200mm in length. Some will be cut into wide or narrow planks, depending upon the style of the floor. 

A machine is then used to install a click system, making installation simple. They may also be given a bevelled edge design during this process. 

Once the planks have been cut to size, it’s time to package them up ready to be shipped to the customer. 

This is a basic overview of how laminate flooring is made. The improvements within the manufacturing process has led to better quality, more realistic designs. 

View our impressive range of laminate floors today to see just how many styles and effects there are to choose from.