How Laminate Floor is Made

Laminate flooring is made up of three layers:

Decorative paper and overlay in melamine resin

Core layer made of HDF, MDF or particleboard

Stabilizing layer made of special paper

The decorative paper is what gives the laminate flooring its individual appearance. There are a wide range of innovative and highly authentic wood reproduction decorative coverings, but the large variety of interesting reproduction tile designs and fantasy decorative coverings should not be forgotten either. The wear layer is provided by the melamine resin, a highly wear resistant material that makes laminate flooring so hard wearing.

The core of the laminate floor is provided by the core layer. As its name suggests, this supports the decorative paper and the overlay, and of course the people who later walk on the floor. The core layer is made of either HDF (High Density Fibreboard), MDF (Medium Density Fibreboard) or particleboard. A variety of other different papers can also be inserted between the core layer and the decorative paper, e.g. a footstep sound insulation layer.

The stabilizing layer makes up the bottom layer of laminate flooring and is what gives the floor its stability.

Laminate flooring is produced in board form. The production process involves the individual layers in the laminate floor being pressed together under high pressure and at high temperature. There are two different production processes currently in use: DPL (Direct Pressure Laminate) and HPL (High Pressure Laminate).

DPL
In the direct-pressure laminate process the decorative covering layer and stabilizing layer are pressed together onto the core layer.

Composition of a direct-pressure laminate floor (DPL)

Overlay (wear layer)
Decorative paper
Core layer
Stabilizing layer

HPL
In the high-pressure laminate process, on the other hand, the decorative paper and overlay are pressed onto special high-strength paper first. Only in a second stage is this so-called high-pressure laminate glued to the core layer.

Composition of a high-pressure laminate floor (HPL)

Overlay (wear layer)
HPL (decorative paper + high-strength paper)
Core layer
Stabilizing layer

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