The present invention relates to a door skin comprising an exterior surface having outer portions lying on a first plane, spaced grooves recessed from the plane of the outer portions, and tonal portions having a planar area and a plurality of spaced depressions recessed from the plane of said planar area. The present invention is also directed to a method of etching a plate, for use with a molded die set, for embossing a wood grain pattern in the door skin, and the etched plate formed therefrom.

A door skin featuring a facing having an exterior surface and an interior surface can be provided. A wood grain pattern portion can be formed in the exterior surface of the facing. The wood grain pattern portion can feature a plurality of grooves formed in the exterior surface of the facing, the grooves are recessed from a first plane of the exterior surface, and tonal portions formed in the exterior surface of the facing. The tonal portions can include at least a first protrusion, a second protrusion, and a third protrusion. Spacing between the first protrusion and the second protrusion can be different from spacing between the second protrusion and the third protrusion.

Processes for manufacturing surface elements are disclosed. The surface elements can comprise a decorative upper layer and a supporting core. Processes for manufacturing such surface elements can comprise obtaining a decor at least by digitization of a number of archetypes selected from woods and minerals by making a high resolution digital picture of said archetypes, storing said decor digitally, manufacturing a plurality of supporting cores, each being of rectangular shape and each having a size essentially equaling only one desired end user format and provided with an upper side and a lower side, editing said decor to fit said shape and size of each one of said plurality of supporting cores, and digitally applying different patterns on each of said plurality of supporting cores, wherein said patterns are selected and parted from said decor and said decor is used to control said digitally applying the different patterns.

Processes for manufacturing surface elements are provided. The surface elements can include a decorative upper layer and a supporting core. Processes for manufacturing such surface elements can comprise manufacturing a supporting core having a format essentially equaling the desired end user format and provided with an upper side and a lower side, providing a ground coating on the supporting core, and applying a digitally printed dcor comprising inks of at least four colors directly on top of the ground coating by means of an ink-jet type printer, said four colors comprising one or more colors different from cyan, magenta, yellow and black; said digitally printed dcor being one of wood or mineral, and providing and curing an at least partly translucent wear layer on the upper side of the supporting core.

Processes for manufacturing surface elements are provided. The surface elements can comprise a decorative upper layer and a supporting core. Processes for manufacturing such surface elements can comprise manufacturing a supporting core having an upper side, treating said upper side of said supporting core, including at least one of the steps of ground coating with a primer, sanding and providing said upper side with a surface structure, applying a digitally printed dcor comprising inks of at least four colors directly on top of the ground coating by an ink-jet type printer, said digitally printed decor being one of wood or mineral, and providing and curing a protecting and at least partly translucent wear layer on the upper side of the supporting core.

A nonwoven fabric is disclosed. The nonwoven fabric can include a first surface and a second surface and at least a first visually discernible zone of three-dimensional features on one of the first or second surface. Each of the three-dimensional features can define a microzone comprising a first region and a second region. The first and second regions can have a difference in values for an intensive property, and the first visually discernible zone can exhibit a high visual resolution.

A nonwoven fabric is disclosed. The nonwoven fabric can include a first surface and a second surface and at least a first visually discernible zone of three-dimensional features on one of the first or second surface. Each of the three-dimensional features can define a microzone comprising a first region and a second region. The first and second regions can have a difference in values for an intensive property, and the first visually discernible zone can exhibit a high visual resolution.