Composite door structure and method of forming a composite door structure

A method of forming a door facing for assembly on a door frame, comprising:

• mixing a thermoplastic polymer with an organic fibrous material to form a mixture in a ratio such that the organic fibrous material constitutes 40 to 60 percent by weight of the mixture;
• extruding the mixture under heat and pressure to form a thin sheet;
• cutting the sheet to a predetermined size;
• and
• thermoforming the sheet to impart on at least one surface an exterior three dimensional door surface to define a thin door facing.

A method of forming a door facing for assembly on a door frame, comprising:

• mixing a polypropylene with an organic fibrous material to form a mixture;
• extruding the mixture under heat and pressure to create a thin sheet;
• cutting the sheet to a predetermined size;
• and
• thermoforming the sheet to impart to at least one surface an exterior three dimensional door surface to define a thin door facing.