Locally Made Plantation Shutters

How We Build Shutters

Step into our state-of-the-art shutter manufacturing facility located just outside Charlotte, NC, and explore our proven 10-step process. At our facility, we take full control of every stage, ensuring the creation of the highest quality plantation shutters in Charlotte. As the oldest and most technologically advanced shutter manufacturer in the area, we’re committed to delivering the best plantation shutters.

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.

A man in a blue shirt stocks long white lumber vertically on a wall

Step 2 – Initial Cutting

Our craftsmen meticulously cut louvers, available in various 2.5 inch, 3.4 inch and 4.5 inch, to control light and privacy. Alongside, we prepare the control rod, the backbone that links these louvers together.

A technician cutting plantation shutter lovers with an automated radial arm saw.

Step 3 – Stapling Louvers

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 Rails

Rails — horizontal pieces that frame the louvers—are prepared. Automated machinery drills holes, applies glue, and inserts 4 wooden dowels, ensuring structural integrity. The same machine routes out a mouse hole for the control rod to close into.

A machine drills holes and inserts glue and dowels to the top rail of a shutter.

A spout distributes glue and pushes dowels into place

A large router machines out the top mouse hole on a plantation shutter rail.

A large router bit routes out a mouse hole for the control rod

Two completed rails have their dowels are ready for assembly

The machine simultaneously completes the dowels in both the top and bottom rail

Step 5 – Preparing Stiles

Side stiles—vertical pieces that frame the louvers—are prepared. Holes for the louver pins, tension screws, and even hinges are pre-drilled.

A machine drills holes in shutter stiles

A diagram points out dowel holes and louver holes in a shutter stile

Holes are drilled into the stiles for tension screws and hinges

Step 6 – Panel Assembly & Sanding

Here, the louvers, stiles, and rails come together and are joined via the dowel rods on a specialized slatted table. The panel is cut to its final dimensions, and imperfections are sanded off.

A worker assembles all the cut shutter pieces into a finished panels

A worker assembles all the shutter pieces into a finished panel

A worker cuts the finished shutter panels down to size

A worker cuts down the assembled shutter panels to its final size

A worker sands down and paints any imperfections found during manufacturing

Step 7 – Frame Cutting

Simultaneously, an outer frame is machined and the frame is prepared to receive the Hoffman Keys, known for their unparalleled strength in wood joining.

A worker cuts the outer frame for the shutter

Step 8 – Painting

Each component is carefully painted in a dedicated space, ensuring a flawless finish. 3 strokes are sprayed by hand for premium, high-quality finish.

A worker paints a plantation shutter by hand in a spray booth

Step 9 – Framing & Assembly

A finishing technician assembles the outer frames to the completed shutter panel. The outer frames are joined using sturdy Hoffman Keys to connect. In addition, he adds magnets and hinges to the frames.

A worker measures and assembles a plantation shutter to its frame

Hoffman Keys are used at the frame miters for easy assembly and join durability

plantation-shutter-hinges

Hinges are attached to the frame and panel so that the panel is able to swing open and closed

plantation-shutter-magnets

Magnets are attached to the frame to keep the panels in tact

Step 10 – Quality Control & Staging

Panels go through a final quality inspection, and any unsatisfactory shutters are sent back to the factory. The shutters are then packaged in bubble wrap and readied for local Charlotte delivery.