Our Process

Have you ever wondered how to build a plantation shutter? This how-to guide walks you through each step of our shutter manufacturing process. Combining the precision of high-tech machinery with the skilled hands of experienced craftsmen, we've refined the art of shutter-making right here in Monroe, North Carolina.

Step 1 - Raw Materials

Our journey starts with high-grade, pre-primed basswood delivered in large pallets. Every piece is inspected for quality to ensure it meets our high standards.

Why Basswood? Learn More >

Step 2 - Initial Cutting

Our craftsmen meticulously cut louvers, available in various sizes, to control light and privacy. Alongside, we prepare the control rod, the backbone that links these louvers together.

Step 3 - Stapling & Pre-Assembly

An automated machine staples each louver to the control rod. Concurrently, pneumatic drills make the necessary side holes for pins, setting the stage for the louver-to-stile connection.

Step 4 - Preparing Supports

Side stiles—vertical pieces that frame the louvers—are prepared. Their holes are drilled with precision, setting the stage for the attachment of louvers and rails.

Step 5 - Rail Processing

Top and bottom rails are also machine-prepared. Automated machinery drills holes, applies glue, and inserts dowels, ensuring structural integrity.

Step 6 - Panel Assembly

Here, the louvers, stiles, and rails come together. Assembled on a specialized table, imperfections are sanded off and the panel is cut to its final dimensions.

Step 7 - Frame Cutting

Simultaneously, an outer frame is machined with a meticulous eye. Precision cuts are made, and the frame is prepared to receive the Hoffman Keys, known for their unparalleled strength in wood joining.

Step 8 - Painting & Finishing

Each component is carefully painted in a dedicated space, ensuring a flawless finish. Multiple strokes are applied for premium, high-quality finish.

Step 9 - Frame Assembly

The outer frames are joined using sturdy Hoffman Keys to connect. This technique eliminates the need for nails or screws, offering a clean and durable join.

Step 10 - Quality Check & Staging

Hinges are added to the assembled panels and frames. After a final quality inspection, the shutters are packaged and readied for local delivery.