Inside Debar’s Manufacturing Process: How We Create High-Performance Hardware

When systems houses and fabricators choose Debar for their bi-fold door hardware, they are investing in proven performance, durability and over 30 years of engineering expertise.

To better understand how we produce such high-performance hardware, we went behind the scenes, and sat down with Ben Fawthrop, our Operations Director, to discuss how Debar manufactures premium hardware and why quality remains at the heart of everything we do.

For us, high-performance bi-fold door hardware is not simply about appearance or functionality on day one. It means producing products that continue to perform year after year in demanding real-world environments.

It is a critical aspect of the business and something we take real pride in. We want the end user to know they are buying a premium product from the moment they use it.

That confidence is backed by longevity. Most of our products are supplied with a 10-year guarantee, reflecting our commitment to reliability and long-term value.

Every Debar product begins with our technical team, who lead the early design, trialling and sampling stages. Once drawings are approved, the project moves into operations, where this team takes over.

At that point, we review every part and work out the best way to manufacture it. We also carry out a costing analysis to determine whether it is more efficient to produce in-house or source through trusted third-party specialists.

That decision depends on the component type. Our manufacturing model combines in-house expertise with specialist supply partners to achieve the best possible result.

For example:

• Die-cast components are highly technical and are typically subcontracted to specialist manufacturers.
• Turned components are produced using advanced lathes, with some outsourced depending on demand and complexity.
• CNC-machined parts such as rollers and hinges are often manufactured in-house using our own machinery and expertise.
• Powder coating is now completed internally after we invested £1 million into a dedicated paint plant
• Final assembly is completed once all components have passed quality approval.

Once approved, products move into full production runs, with quality checks monitoring every stage.

Our production planning is tailored depending on the product type. For bespoke systems, we work closely with the sales manager to schedule production and shipment in line with customer launch dates.

For parts that can be used across multiple bi-fold systems, we provide the sales team with all product information through our NPPI process, enabling products to be introduced quickly and marketed effectively. After launch, we regroup to review the process and identify any improvements for future projects.

Strong products begin with the right raw materials. Our technical team specifies materials during the design stage, ensuring each part is matched to its intended application.

Once drawings are complete, our programmers and production teams determine the quantities, sizes and machining requirements needed.

We work with a range of materials depending on the product, including:

• Aluminium
• Stainless steel
• Specialist alloys
• Engineering plastics

Different tooling is used depending on the material being processed, ensuring precision and consistency across every batch.

Quality assurance at Debar is not limited to final inspection. It is embedded throughout production as we use various gauges at every stage. Depending on the process, parts are checked for accuracy, fit and finish before they move forward.

These checks take place across:

• Goods-In Inspection

• Sawing
• CNC machining
• Paint finishing
• Assembly

Some inspections use fixed gauges that provide a simple pass-or-fail result, ensuring accurate dimensions quickly and consistently. We also apply supplier scoring systems to monitor third-party performance. If repeated faults are identified from a supplier, incoming goods are subjected to higher AQL checks by the goods-in team.

If anything fails, our quality team steps in and checks all related stock. It can slow the process down, but protecting the quality of our hardware always comes first. This approach is supported by our wider total quality management system.

While modern machinery is essential, we believe people remain just as important as technology. We are proud to develop people internally. We don’t often bring in external specialists and instead create opportunities for our own team to step up.

Recently, when a key programmer retired, we already had an apprentice in place who had spent four years developing the skills needed to step into the role.

This highlights that technology and training go hand in hand at Debar. Our employees are given the opportunity to train across departments, creating a cross-skilled workforce that can move between areas as production demands change and allowing our staff to develop their own skills.

Before products reach customers, we rigorously test them to ensure long-term reliability against various climates.

We use a range of in-house testing methods, including:

• Salt spray testing to assess corrosion resistance, especially for new parts
• Cycle jig testing, where products are repeatedly opened and closed to simulate years of use
• Stress testing for die-cast components
• Scratch testing within the paint plant to assess coating durability

These tests are particularly important when launching new systems, changing a system’s components or introducing new suppliers to the production of a system.

We continue to invest in both productivity and sustainability through continuous improvement initiatives. We have established a dedicated improvement team made up of colleagues from different departments, tasked with identifying better ways of working.

Our current projects include:

• Exploring cobots for machining support
• Additional automation systems in the pipeline
• Improved internal non-conformance monitoring to identify root causes faster
• Expanded staff training pathways and development programmes
• Identifying cost savings through efficiency improvements and sustainable packaging and processing methods
• Ongoing employee engagement initiatives

For us, the future of manufacturing lies in combining smart automation with skilled, motivated people.

Our manufacturing process reflects our commitment to quality, precision, innovation and longevity. From selecting materials and machining them to testing and final assembly, every stage is designed to deliver bi-fold door hardware that performs for years to come.

As Ben makes clear, our premium hardware has been built through our expertise, years of investment and a commitment to getting every detail right.

If you’re looking for a new hardware supplier for your bi-fold door system, get in touch with our team today.