How Are Double-glazed Windows and Doors Manufactured?

Today, double-glazed (double-glazed) doors and windows are widely utilized and popular due to their numerous advantages. However, are you acquainted with the process of manufacturing these types of doors and windows? The construction of such doors and windows necessitates the use of specialized technologies and appropriate workshop space. In this article, our aim is to delve deeper into the construction of uPVC double-glazed windows and address key considerations related to it. 

Step One: Measuring the Dimensions

The first step involves accurately measuring the dimensions of the door and window. This stage is highly sensitive in the production of double-glazed doors and windows, therefore, experienced individuals should handle this task. Precise dimension measurement is achieved using a laser meter tool.

Step Two: Design and Production

In the second step, an experienced individual uses specialized software to design the door and window, taking into account the dimensions. One of the most well-known software programs used for this purpose is Iwindoor. The design phase of the project holds significant importance, as it directly impacts the durability and aesthetic appeal of the final product.

Step Three: Cutting the Profiles

Next, the uPVC profiles are cut using a double-head cutting machine. This prepares the profiles for the subsequent stages. If you pay attention to the construction of uPVC double-glazed windows, you will realize that the double-head cutting machine is one of the most important devices used for this purpose. This machine cuts the profile branches from both sides, shaping the corners of the profile as desired (e.g., triangular shape), thus shaping the corners of the window.

Step Four: Cutting the Galvanized Profiles

Galvanized profiles made of steel with various thicknesses ranging from 0.7 millimeters to 2 millimeters are used to strengthen and stabilize the uPVC profiles in the window. The galvanized sheets prevent the sashes from sagging and protect the window from external damage and pressure. The thicker the galvanized sheets used, the higher the price of the double-glazed window.

Step Five: Mullion Profile Production

After the cutting stages of the profiles are completed, the mullion profile, also known as the T-profile, needs to be produced. This profile is placed in the middle of the door and window as a frame. A mullion drilling tool is used to produce the mullion profile, shaping the profile. Finally, a mullion connector, or mullion lock, is installed on the mullion profile. Ultimately, it is connected and strengthened with locks and pegs to the galvanized sheet inside the profile.

Step Six: Grooving Profile and Handle

In this stage, two grooves need to be created in the profile. The first groove in the front part is for various types of handles, and the second groove at the back of the profile is for water drainage. The profile grooving stage is carried out using a water groove and handle grooving machine. Additionally, a grooving machine is used to create a hole in the handle hardware of the window.

Step Seven: Welding the Prepared Frames

After the profiles are cut and prepared, it's time to weld them. A double-head welding machine is used for this stage. Initially, the upper frame is placed inside the double-head welding machine, followed by the right and left frames. Finally, the machine is turned on to weld the frames. Once the welding stages of the upper window frames are completed, the lower frames are also welded. Ultimately, the main frame is formed and ready for use in the next stage.

Step Eight: Connecting Mullion Profile

Before explaining the mullion profile connection stage, it is necessary to know more about the structure of the double-glazed window frame. Generally, window frames are defined in two parts.

The Fixed Part of the Window

As the name implies, this section of the window is entirely fixed and does not have the capability to open.

The Opening Part of the Window

This part is essentially where the handle is installed and used to open the window. During the mullion profile connection stage, the mullion profile is placed in the middle of the window frame, and then it is firmly secured with locks and screws. As a result, two parts of the window are created, one of which is fixed, and the other is placed in the opening position. The fixed part needs to be weather-stripped to accommodate the glass, and the opening part is inserted into a device called a profile cleaner. This process ensures that the corners of the profiles are cleaned for easier installation of hardware and a more aesthetic appearance.

Step Nine: Installing the Hinges

In this stage, the window and door hardware is installed. Initially, templates are installed, and then holes are drilled using a drill. Subsequently, handles, hinges, and hardware are installed.

Glazing

In the final step, plastic parts are used to glaze the window, and the glass is installed. Then, uPVC beads are placed on the double-glazed window to secure the glass.

Concluding Remarks

Have you ever wondered how double-glazed windows are made? The construction stages of double-glazed windows are divided into different steps, and each step involves the construction of a part of the window. In this article, we have discussed the methods of making double-glazed windows and explained each stage in detail.