Cost reduction initiatives are becoming increasingly important to airframe manufacturers. Conversion of built-up assemblies to monolithic components is a recognized method for reducing the installed costs of aerostructures via: decreased assembly time, reduced floorspace requirements, less inventory, fewer invoices, diminished print administration, etc. Aircraft doors have historically been designed with large numbers of small, detailed parts requiring many fasteners. Hence, the reason that doors and their surrounding frames can represent as much as 35-40% of the cost of transport aircraft fuselage structure. Conversion of such structure to a few monolithic components can greatly reduce cost. However, crafting robust manufacturing processes for structures with buy-to-fly ratios in the neighborhood of forty (40) is no small task. Efficient conversions require attention during both design and development of the manufacturing plan. Residual stress control and corresponding material choices are paramount to success - the true measure of which is found in negligible machining distortion and an optimized integral structure. This presentation will address some of these factors and provide examples for several classes of doors.