Learning how laminate is manufactured is easy and simple. We’ve outlined the
basics below and ask that you read through them to better understand how this unique
product is created.
Knowing how laminate is constructed provides you with knowledge of laminate right
from its beginning. That’s important information because these are the materials
you’ll be living with and walking on for years to come should you choose this
Knowing laminate construction also helps you better understand and evaluate its
So read on, and we’ll do our best to help you know how laminate is made, the
various steps involved, and the reasons why certain processes are performed.
In the section “Introduction to Laminate,” we told you laminate is a
manufactured product that is a true look-a-like of hardwood flooring, natural stone
and many other types of flooring.
Now, you may be wondering, how can laminate flooring resemble these other products
The answer lies in the process of how laminate is made.
It’s a combination of the precision of today’s manufacturing techniques
and the expertise of the men and women behind the materials, machines and methods
that create laminate.
All work in harmony to produce a beautiful, functional flooring that closely simulates
other beautiful, functional floorings.
To know laminate, think baking and a four-layer cake.
Today’s laminate floors are available in a multitude of designs, patterns,
and textures, yet they all consist of four main components that are bonded together.
The bottom layer, or backing, is a melamine plastic layer that lends dimensional
stability to the planks and also helps guard against moisture from the sub-floor.
(Moisture infiltrating any flooring is the enemy.)
The next layer is a core board, generally made from high-density fiberboard or particle
board which may also contain melamine plastic resins that help improve the moisture
resistance of the core.
Then a decorative layer or print film is adhered on top of the core board giving
the floor its hardwood or tile look.
This decorative layer is a printed high-resolution photo-reproduction of wood grain,
natural stone or ceramic tile pattern. (Now you know how the look-a-like is born.)
And the frosting? On the top of our “cake” is a durable wear layer,
providing protection and stain resistance.
Now many wear layers also contain aluminum oxide, as well as melamine resin, and
that creates exceptional durability. The kind that will stand up to the most active
household – even yours.
All four layers of our “cake” are then combined in a high-pressure process.
Now we’ll take you through the manufacturing process of laminate one step
at a time.