Abstract: The present invention provides a method for manufacturing a door for a walk-in bathtub, which comprises forming a tub door cap from an acrylic sheet, wherein the tub door cap has an outer shape defining a door for a walk-in tub; forming a channel into a surface of the tub door cap along a peripheral area thereof; forming a threshold portion configured to mate with the channel in the tub door cap and extend outwardly from the tub door cap; and the tub door cap is then adhered to the threshold portion of the door to form a walk-in tub door. The acrylic sheet that forms the tub door cap may be cast acrylic or it may be reinforced by co-extruding with thermoplastic, adding a reinforcing filler and/or fiberglass. A walk-in bathtub door made by the method described above and a walk-in bathtub assembly having a door made by the method described above are also provided herein.

Abstract: The present invention provides a method for manufacturing a door for a walk-in bathtub, which comprises forming a tub door cap from an acrylic sheet, wherein the tub door cap has an outer shape defining a door for a walk-in tub; forming a channel into a surface of the tub door cap along a peripheral area thereof; forming a threshold portion configured to mate with the channel in the tub door cap and extend outwardly from the tub door cap; and the tub door cap is then adhered to the threshold portion of the door to form a walk-in tub door. The acrylic sheet that forms the tub door cap may be cast acrylic or it may be reinforced by co-extruding with thermoplastic, adding a reinforcing filler and/or fiberglass. A walk-in bathtub door made by the method described above and a walk-in bathtub assembly having a door made by the method described above are also provided herein.