How Are Our Door Canopies Made?

If you're considering adding a door canopy to your home, it’s helpful to understand what goes into making one. At Apex Canopies, each canopy goes through a detailed manufacturing process that ensures it’s strong, reliable, and ready to install.

From the initial extrusion of our Woodex timber material to careful measuring, cutting, fabricating and final packing, every stage is designed to produce a long-lasting product that’s simple to assemble and install. In this guide, we’ll walk you through exactly how our door canopies are made, step by step, from raw materials to the moment your order is delivered.

Step 1: Extruding the Door Canopy Materials

At Apex Canopies we use Woodex timber to manufacture our canopies as it is the best material option available. This is because it is extremely strong, lightweight (easily installable), infinitely customisable and incredibly long-lasting.

The creation of our Woodex timber takes place in Droitwich at Ram Extrusion. Here, a blend of recycled and prime polymers is melted down into a thick, gooey substance. This molten plastic is then pushed through a die (a mould) to form a continuous length of Woodex material. Once shaped, the profile is water-cooled to solidify it, ready for the next stage.

Step 2: Forming the Door Canopy

Once the Woodex is extruded, it’s delivered to our factory in Malvern. Our door canopies are made to order to ensure that they are as customizable as possible. Once we get your order, our carpenters start by assessing the digital design and cutting the Woodex to size and shape using our CNC saw unit to ensure accuracy. For pitched and apex canopies the rafter ends are cut at the correct angle to neatly meet at the ridge/top of the canopy. We cut traditional mortise and tenon joints to make assembly simple and ultra-secure to ensure easy installation for our customers. Finally, the truss (apex canopy only) is fitted.

Step 3: Inspecting and Packing Your Door Canopy for Delivery

Once your canopy has been expertly assembled, It is carefully inspected to ensure our high-quality standards have been met. When the door canopy inspection is complete it is carefully flat-packed into a sturdy cardboard box or palletised, with protective materials like bubble wrap and foam inserts to keep every component safe in transit. We also include a full fixing kit with every canopy, so you’ll have everything you need for installation. Your canopy is then handed over to one of our trusted courier partners for fast, secure delivery.

Final Summary - How Are Door Canopies Made? (Step-by-Step)

Door canopies go through a careful design and manufacturing process to maximise strength, durability, and allow easy installation. Here’s a concise breakdown of the production steps:

1. Selecting & Preparing Materials
Quality materials are carefully selected, measured, and prepared based on the canopy’s design.

2. Measuring & Cutting Components
Materials are precisely measured and cut using computer-controlled saws and tools. Angled joints are made for canopy styles such as apex or pitched.

3. Preparing & Shaping Joints
Mortise-and-tenon, lap, or dowel joints are accurately shaped and drilled to securely connect canopy parts, ensuring strength and stability.

4. Assembling the Canopy Frame
Components are expertly joined using screws, dowels and our specially formulated Woodex chemical adhesive to form the canopy frame. The assembled frame is checked carefully to ensure alignment, accuracy, and durability.

5. Finishing & Surface Treatment
If needed, the canopy can be de-nibbed, painted, or coated with a textured finish to give you the most aesthetically pleasing finished canopy to enhance the look of any home.

6. Quality Inspection & Packaging
Each canopy undergoes a thorough quality check, then is carefully flat-packed or palletised with protective packaging to prevent damage during shipping.

Final Thoughts:

Now that you've seen the care and craftsmanship that goes into every Apex door canopy, the next question is: how easy is it to install? The good news is we’ve designed our canopies with DIY installation in mind. Find out exactly what’s involved in installing a door canopy here.

🛒Shop by Canopy Style: Apex | Pitched | Flat
🧰See our Installation Guide & FAQs