How Integra Makes Windows and Doors

When you're investing in uPVC windows and uPVC doors for your home, understanding how they're manufactured matters. At Integra, we combine European engineering with Australian manufacturing to deliver products built to last in our harsh climate. Here's how we make every window and door.

European Materials, Australian Manufacturing

We don't cut corners on materials. Our lead-free uPVC window profiles come from leading European suppliers – the same profiles trusted across Europe for decades. These profiles are shipped to our Sydney warehouse, where our manufacturing process begins. This approach gives us the best of both worlds. European profile technology has been refined over 60 years, while local manufacturing ensures faster turnaround times and products designed for Australian conditions.

Precision Cutting and Profile Preparation

Manufacturing starts with precision. Our automated German cutting equipment cuts uPVC profiles to exact specifications for each order. These aren't off-the-shelf sizes – every frame is cut to match your specific window or door dimensions. The cutting process uses computer-controlled machinery, ensuring accuracy within 0.5mm. This precision matters because even small variations affect how well your windows seal against weather and noise. After cutting, profiles are cleaned and prepared for welding. Any dust or residue is removed to ensure strong, clean joints.

Galvanised Steel Reinforcement

Internal steel reinforcement is what sets quality uPVC windows apart from cheaper alternatives. All our uPVC window and door frames use galvanised steel reinforcement for structural strength. The steel is inserted into the hollow chambers of the uPVC profile before assembly, ensuring rigidity regardless of window size. A CNC screwing centre then secures the reinforcement, placing every screw at the correct position and spacing. This guarantees perfect alignment and ensures no screws are missed during assembly. This is different from aluminium windows, where the metal frame is exposed to the elements. Our steel reinforcement is encased inside the non-conductive uPVC shell. This design is what makes our windows thermally efficient: the uPVC insulates whilst the steel provides strength. It's also why our windows resist corrosion, fire, and extreme weather whilst reducing noise transfer. For larger windows like uPVC bifold doors or uPVC sliding doors, additional reinforcement is added to handle the increased weight and span.

Heat Fusion Welding for Structural Integrity

The frame corners are joined using heat fusion welding, not screws or mechanical fasteners. This process heats the uPVC at the corners until it melts, then presses the pieces together to form a seamless, permanent bond. Four-head welding machines simultaneously join all corners, ensuring perfect alignment. Once cooled, these welded joints are stronger than the profile itself. The excess material is trimmed away, and corners are cleaned for a polished finish. This welding method is why uPVC frames don't separate, twist, or develop gaps over time, unlike mechanically fastened frames.

Glass Supply and Double Glazing

Whilst our frame extrusions come from Europe, we source all glass from Australia's leading suppliers – ACG and Viridian. This means faster delivery and products tested for Australian conditions. Our double glazing process creates insulated glass units (IGUs) with two panes separated by a spacer bar. The gap between panes is filled with argon gas, which has lower thermal conductivity than air. This assembly is what delivers the thermal performance behind our 7-star energy rating. The IGUs are sealed to prevent gas escape and moisture infiltration. Quality sealing is critical – failed seals lead to condensation between panes and loss of insulation performance. We test every seal before installation. For homeowners who want to understand how double glazing works in detail, the science boils down to reducing heat transfer through multiple barriers.

Hardware and Weather Sealing Installation

European hardware from premium manufacturers is fitted to each window and door. Casement windows and awning windows receive multi-point locking systems with sash compression locks to ensure a tight, reliable seal. Tilt and turn windows are equipped with multi-point, gear-operated hardware, where a single turn of the handle engages all locking points, providing both tilt ventilation and full-opening functionality. Continuous weatherstripping is installed around the perimeter of operable sashes. This creates an airtight seal when closed, preventing drafts and water infiltration. All hardware is corrosion-resistant and rated for use in coastal environments, which is essential for installations in NSW and the ACT.

Quality Control Before Dispatch

Every window and door undergoes inspection before leaving our factory. Our team checks:

• Frame dimensions and squareness
• Weld quality and appearance
• Glass installation and seal integrity
• Hardware operation and adjustment
• Weatherseal placement and compression

In addition to these checks, every product is carefully prepared for transport: all frames are wrapped in protective tape, all corners are reinforced with cardboard, and all hardware is individually bubble-wrapped. Products that don't meet our standards are reworked or rejected. This level of quality control is non-negotiable – we don't dispatch anything we wouldn't install in our own homes

Why In-House Manufacturing Matters

Manufacturing in-house gives us control over the entire process. We're not relying on third-party fabricators or waiting on international shipping for custom orders. This control translates to faster turnaround times, typically 4 to 6 weeks from order to delivery. For renovators and builders working to tight schedules, this speed makes a real difference. It also means we can offer custom sizes and configurations without the premium pricing you'd expect. Because we're cutting, welding, and assembling everything ourselves, bespoke doesn't mean months of waiting or excessive costs.

The Result: Energy Efficient Windows Built to Last

The benefits of uPVC windows and doors come directly from how they're made. The combination of European-engineered profiles, precision manufacturing, steel reinforcement, and Australian glass creates products that perform in our climate. Whether you're building new or renovating, understanding the manufacturing process helps you recognise quality. At Integra, we manufacture products we're proud to put our name on – because we control every step from profile cutting to final inspection. Want to see the difference in person? Visit our showrooms in Alexandria, Prestons, or Frenchs Forest to experience our uPVC energy-efficient windows and doors firsthand. Request a quote online or call us to discuss your project.