TRANSFORMING HOMES SINCE 2007
MADE IN BRITAIN
NATIONWIDE SUPPLY & INSTALL SERVICE
World-class door and window manufacturing sits at the core of everything we do at Express Bi-folding Doors. Every aluminium frame, pane of glass, and precision-engineered component begins its journey at our large-scale production facility in Leeds.
Since 2007, we have specialised in designing and fabricating high-performance aluminium systems, managing the entire production process under one roof. Skilled technicians work alongside advanced CNC machinery and rigorous inspection procedures to produce beautifully engineered windows and doors built for durability, strength, and long-term performance.
This behind-the-scenes look explores how modern aluminium fabrication works and how British engineering expertise continues to shape the production of high-quality doors and windows across the UK.
Inside Our UK Door and Window Manufacturing Facility
Our Leeds manufacturing facility has grown into one of the most advanced door and window manufacturing facilities in the UK.
Spanning 200,000 square feet, the manufacturing site employs more than 300 skilled engineers, technicians, and fabricators. Each person plays an important role in producing aluminium doors and windows that meet the high expectations associated with the Express Bi-folding brand.
Producing these products within a single manufacturing facility allows complete oversight of materials, machining, and assembly. This level of control helps ensure reliable quality and consistent lead times.
Managing Director Steve Bromberg explains why keeping production in Britain matters:
“British engineering has a long history of producing exceptional products. By keeping door and window manufacturing here in Leeds, we maintain close oversight of every stage of production. That attention to detail ensures every aluminium door and window leaving our facility reflects the quality people expect.”
How Our Door and Window Manufacturing Process Works
Producing aluminium doors and windows requires several carefully controlled stages, with each contributing to the structural integrity and precision of the final product.
Within our manufacturing facility, aluminium profiles and glazing components move through a structured production process before final inspection and dispatch.
Aluminium Storage and Material Supply
The manufacturing of aluminium doors and windows begins long before production starts on the factory floor. It begins in our dedicated aluminium storage warehouse, where high-quality profiles are carefully organised and prepared for fabrication.
Our facility maintains substantial quantities of aluminium profiles on site, ensuring production can run smoothly without interruption. These profiles arrive regularly from trusted European suppliers, allowing our engineers to work with consistently premium materials.
By maintaining a reliable and well-managed supply of aluminium, our production teams can operate efficiently while delivering a steady output of precision-made aluminium doors and windows. Consistent material sourcing is a crucial part of supporting large-scale manufacturing and maintaining the high standards our customers expect.
Profile Inspection and Surface Protection
Before fabrication begins, each aluminium profile undergoes a detailed inspection process. Technicians carefully examine every profile to ensure the powder-coated finish meets strict standards for colour consistency, durability, and overall quality. Any imperfections are identified and removed from the production flow at this early stage.
Once approved, protective taping is applied to safeguard the aluminium surface during machining and handling throughout the manufacturing facility. This careful preparation ensures that only flawless, protected materials move forward into the door and window fabrication process.
Precision CNC Machining
Once approved, aluminium profiles move into our machining area, where they are shaped using advanced CNC technology. High-performance machining centres carry out drilling, milling, tapping, and cutting across multiple faces of each profile. This process allows our manufacturers to produce frames with tight tolerances, consistent accuracy, and reliable structural strength.
Key capabilities include:
- Multi-face drilling, milling, tapping, and cutting
- High-precision CNC machining for complex aluminium systems
- Consistent tolerances for aluminium doors and windows
In 2024, we became the first fabricator in the UK to order the Emmegi Quadra 20-axis CNC machining centre. This advanced system performs 360° rotary milling, drilling, and tapping on all four faces of the profile, combined with a 360° rotary cutting blade, delivering exceptional precision and production efficiency.
Before components leave the machining area, each one undergoes a final inspection. Profiles are then individually wrapped and prepared for the next stage of production, ensuring every frame meets strict quality and finish standards.
Glass Storage and Preparation
Glazing is a critical component in aluminium doors and windows. Glass units arrive at the manufacturing site from established glass manufacturers specialising in high-performance glazing systems. Each delivery undergoes careful inspection before being stored.
Technicians check:
- Clarity of the glass
- Structural strength
- Compliance with glazing regulations
- Surface cleanliness
Once approved, glass units are stored safely until they are installed within aluminium frames during assembly. Working with experienced glass manufacturers ensures each glazing unit meets strict quality standards required for modern aluminium doors and windows.
Assembly and Final Inspection
Following machining and glazing preparation, aluminium frames move into the assembly stage.
Technicians assemble the aluminium sections while installing hinges, rollers, seals and locking systems. Precision alignment remains essential, particularly for aluminium bifold door systems where smooth operation depends on accurate engineering.
Each product then undergoes detailed inspection where specialists examine:
- Frame alignment
- Finish quality
- Glazing installation
- Hardware performance
- Operational movement
Safely Packaged & stored
Only after passing these checks do the doors and windows move forward for packaging and delivery.
This rigorous inspection process helps ensure every product leaving the manufacturing site reflects the standards expected from leading window manufacturers and bifold manufacturers.
At this stage our experienced installation teams will then load the products and head off to site, or our drivers will deliver the goods on a supply only basis. Either way, we never use sub contractors and deliver all our products in fully equipped vans that have been carefully loaded by our logistics team.
Why UK Door and Window Manufacturing Matters
Manufacturing doors and windows in the UK provides clear benefits in terms of quality, reliability, and accountability. Keeping production local allows us to maintain direct oversight of the manufacturing process, ensuring high engineering standards and consistent production timelines.
It also provides greater control over materials and fabrication, helping ensure every product meets precise specifications while supporting skilled British craftsmanship and engineering expertise.
Combined with advanced machinery and modern production systems, this approach allows our facility to operate at a level associated with world-class manufacturing. When renowned architect and TV presenter George Clarke visited the site, he praised the scale and sophistication of the operation, describing it as “fantastic” and highlighting how impressive it was to see such a well-established manufacturing facility operating here in the UK.
Door and window manufacturing remains a cornerstone of modern British engineering, and our Leeds facility showcases how skilled craftsmanship and advanced technology combine to produce high-quality aluminium doors and windows. Through careful material sourcing, precision machining, and rigorous inspection, every product is built for durability, reliability, and performance.
By keeping production in the UK, we maintain complete control over quality and delivery while supporting local jobs and skills. As Managing Director Steve explains: “It’s about doing things the right way. We’re proud to manufacture here in Leeds, and proud that every product we make carries that mark of British quality.”
To truly appreciate the difference, we invite you to visit our Leeds showroom and experience our products first-hand, or explore our virtual showroom from the comfort of your home. From the first piece of aluminium to the final inspection, every product is crafted with care, skill, and pride; the commitment to excellence that continues to set Express Bi-Folding Doors apart.
Beautiful products for beautiful homes
All expertly manufactured in house
We’re incredibly proud of the quality products that we bespoke manufacture on a daily basis and one of the most satisfying parts of our job is seeing our products installed within finished homes. Take a look through our case studies where every project features products expertly surveyed, manufactured and installed by us.
