Abstract: An embossed plastic panel door including a pair of plastic panel faces, preferably made of polyvinyl chloride, at least one of the plastic panel faces having a preselected design embossed thereon, and a relatively rigid polystyrene core having the same preselected design burned onto its facing surface. The embossed design is stretch embossed on each of the plastic panels and is burned into the core with a heated die. The core is then covered with heated adhesive and the plastic facing panels are placed on the opposing major surfaces of the core with the designs on the panels in alignment with the burned-in designs on the core and the panels and core are pressed together to form the completed door. A wooden perimeter frame may be placed around the core prior to securing the plastic panel faces thereon in order to provide a thermal brake and increase the structural definition.