10 Mar 2026•Blackline Studio•11 min read
Main Door DesignCase StudyMetal Work
This case study walks through how we designed and fabricated a custom metal main door for a residential project. We share the brief, design options we considered, material and finish choices, and what we’d do again or differently—so you can use it as a reference for your own entrance.
The brief
The client wanted a main door that felt modern and secure, matched the foyer’s neutral palette, and used metal and glass. Key requirements: single-leaf hinged door (no pivot), privacy without blocking all light, and a finish that would hold up in local weather. Opening size and swing were fixed by the existing frame.
Design direction we took
We proposed a slim metal frame (MS, rectangular sections) with a large frosted glass infill and a smaller clear strip at eye level for visibility. The frame was designed with clean joints and no visible screws on the face; hardware was selected for durability and smooth operation. We kept lines horizontal and vertical to align with the foyer’s geometry.
- Frame: MS, rectangular profile, welded and ground for clean seams.
- Glass: toughened frosted with a clear band; fixed with neoprene gaskets.
- Finish: matte black powder coat for consistency with railing and other metal in the home.
- Hardware: heavy-duty hinges and a mortise lock suited for a main entrance.
Fabrication and installation
Frame was fabricated in our workshop, trial-fitted with glass, then dismantled for powder coating. After coating, we reinstalled glass and hardware and delivered as a single unit. On site we checked plumb and level, fixed the frame, hung the leaf, and sealed the perimeter. Total time from design freeze to handover was about four weeks.
What we’d repeat and what we’d refine
We’d repeat: clear brief documentation, one material/finish language with the rest of the metal in the home, and doing frame and finish in-house. We’d refine: even earlier confirmation of lock and hinge dimensions to avoid last-minute adjustments, and a site check list for client sign-off before coating.
“A custom metal main door succeeds when design, material, and installation are treated as one system—not three separate steps.
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