1. All windows start out in our lineal department and come in many colors and variations.

2. Both frames and sashes are cut in a computerized machine that knows specific sizes which are based on an ID number.

3. Products are cut for exact size. They are then tagged with an ID like this. Matching ID labels for all parts will come together in the end of the process for complete assembly.

4. All frame and sash lineals then come to the prep area where they are cleaned with pressurized air. This will ensure there is no shavings or dirt inside the lineals.

5. The next step in our process is one of the most exciting. Both the sash and the frame will come to our four point welders. All four precut frames are put into the welder. The machine calibrates based on the product ID. The first process is to have what is called a “hot plate” heat the vinyl at a temperature of 270 degrees fahrenheit. This is all done at a 45 degree angle. After a set time, the hot plate will pull out and the 90 degree press will come into place to apply even pressure for a set amount of time. This ensures a strong weld. Both frames and sashes will go through the same process.

6. All excess vinyl must be cleaned from the frames and sashes using a machine that acts like a bunch of chisels, cleaning the corners of the welded surfaces. This process is also achieved by good, old-fashioned human touch and elbow grease.

7. At the other end of our 50,000 sq. ft. facility, the glass is being cut according to a computer ID and tag by a diamond blade glass cutter. The glass is scored and then excess glass will be removed to get the exact size of your glass pane. This will be put onto our glass cart to enter the next process.

8. Now we are ready to assemble your energy efficiency. The glass panes will go to Joe in glass pack assembly. First, we apply the thermalset rubberized composite to the glass with a heat gun that will bond it to the glass surface. Once the material is applied all the way around, our clean surface glass lift will rise and the next pane will be applied. The glass pack then rolls through this machine that heats the last pane so the rubberized composite and glass panes are attached and sealed.

9.The next step is a display of quality control at its best. Injecting the gas takes special care. One needle will inject the argon into the glass pack at one end. At the other end there is another needle extracting the air. Once the glass pack has reached maximum capacity of gas, a light will flash. The needles are pulled out and simultaneously a mylar tape is applied over the holes to ensure the gas does not escape.

10. Just as the glass packs are filled with argon, they are immediately given to Stan in the butyl application department. This will add one extra seal for the most superior thermopane in the industry. A hot butyl melt seal is applied all around the perimeter by the machine shown above. Then, they are touched up in the corners and put on the glass pack rack.

11. Now, all parts must be put together where the frame, sash, and glass pack will meet to be assembled. Glass packs are placed into sashes. Glazing beads will be applied to trim the glass and sash.

12. The final step is to assemble the sashes to the frame and apply the locks, hardware, and screens.

13. Packaging your Worthington Windows® will ensure your finished product is delivered with utmost care. All Worthington Windows® are shrink wrapped before going to our truck for delivery.

14. We are proud to share how our Worthington Windows® are manufactured. If you have any questions please do not hesitate to call us at (888) 600-4363.