We recently had cause to examine my sister's cabinet doors very very closely. In doing so, we discovered tiny little shims wedged between the panel and the frame on the back side of the cabinet door. They are so tiny that we didn't see them until we got close and looked carefully. Perhaps your cabinetmaker could put some little bitty shims around the back side of your door to alleviate the problem.

They are made to be able to expand and contract with the change in humidity...yes there are several things that can be done during the manufacturing process that could minimize the "rattle" but there is always a chance that it will be there

You could add in a couple small shims from the back to help hold it in place if it bothers you as bbstx suggested

And even though this is the only one that is doing it doesn't mean that it was made wrong or different then the others...wood is a natural product and each piece can and will react differently to humidity change etc..

I would not bother replacing the door, then the next thing will be the color doesn't match or the profile is a little different etc....

rlhmass:

Lay an inch long bead of clear silicone in four spots on the back of the door between the panel and frame. It will be enough to stop the rattle, but not enough to impede wood movement. If it doesn't work, it's reversible.

Do you have another door the same size? If so, you could switch them.

This post was edited by Trebruchet on Thu, Apr 3, 14 at 13:59

Do what Trebruchet said! Both things.