Method of making multi-ply door core, multi-ply door core, and door manufactured therewith

A method of forming a multi-ply core component, comprising the steps of:

• providing a mold press having an upper die and a lower die defining a mold cavity, at least one of the upper die and the lower die having a plurality of protrusions;
• disposing a first wood composite board and a second wood composite board within the mold cavity;
• and
• fusing the first and second boards proximate the plurality of protrusions by compressing the first and second boards in the mold cavity through application of heat and a pressure of about 400 to about 850 psi and forming high-density portions proximate the plurality of protrusions and low-density portions adjacent the high-density portions,
• wherein the first and second boards are fused in the high-density portions.