Method for assembly of recessed panel doors

A method for making a door assembly of the kind having an internal frame, a core, and first and second door skins attached to the frame on either side of the core, wherein each of the door skins has a planar portion bordering at least one recessed panel portion, said method comprising:

• seating a lower die section against a lower platen of a press so that a base of the lower die section is supported on the lower platen and a raised section of the lower die section stands off from the base thereof;
• attaching an upper die section to an upper platen of the press so that a base of the upper die section is supported by the upper platen and a raised section of the upper die section stands off from the base thereof;
• positioning a stack of door components within the press, including:
• positioning a first door skin in the press with a recessed panel portion of the first door skin facing downward and contacting the raised section of the lower die section,
• positioning a frame in the press over the first door skin, the frame defining a cavity,
• positioning a compressible core in the press overlying the first door skin and within the cavity defined by the frame, and
• positioning a second door skin in the press overlying the compressible core and the frame, with a recessed panel portion of the second door skin facing upward;
• closing the press so that the raised section of the upper die section contacts the recessed panel portion of the second door skin;
• and
• pressing the stack of door components between the lower and upper platens of the press with the recessed panel portions of the first and second door skins supported by the raised sections of the lower and upper die sections, respectively, so that the recessed panel portions compress and deform a portion of the compressible core of the door assembly underlying the recessed panel portions, to thereby form a door assembly.