This study was carried out to evaluate the feasibility of using HDF as surface panels as well as core materials for flush door manufacturing. Several core compositions were developed and applied to manufacture door specimens. Core materials were tested under bending load, door manufacturing process was analysed to find better way of using HDF for door manufacturing, and door specimens were tested under bending, twisting and impact loads. From this study, it was concluded that HDF can be used to manufacture quality flush doors. And it was desirable to use light color HDF as surface panels because dark color HDF caused a problem in manufacturing process by shadow shown through finishing veneer. HDF doors were light, and showed good quality and higher resistance against bending twisting and impact loads.