4 Dec. 2024: VTT Technical Research Centre of Finland has collaborated with Aalto University and Finnish industrial partners to develop a new technology for cardboard shaping, a continuous process to create reel-to-reel origami-inspired structures for fibre-based packaging materials.
According to VTT, the origami folds have the capacity to yield ‘entirely new properties’ from cardboard, and the structures’ light weight and durability provide a visually appealing alternative to conventional protective packing materials like plastic and expanded polystyrene.
Involving 13 different companies, organisations, and universities at various stages, the FOLD and FOLD2 projects aim to renew and expand how cardboard is used as a packaging material. In addition to VTT and Aalto University, the FOLD project involves companies such as Metsä Board, Soften, and Stora Enso; the FOLD2 project includes VTT, Aalto University, Anpap, Mirka, and Walki.
The two-phase project began with designing a machine to fold the origami cardboard, with the next phase of the project set to begin testing other materials. The outcome has reportedly led to new applications of cardboard to manufacture flexible, durable and versatile packaging material.
“Origami folding transforms cardboard into a flexible, protective, and visually appealing material unlike anything that’s previously been available for industry-wide production. The technology we’ve developed also has the capacity to produce foldable materials from recycled goods,” says Jarmo Kouko, creator of the FOLD project and research team leader at VTT.
Origami is traditionally handcrafted, taking several hours to construct by hand which would usually be a limitation for commercial packaging. VTT states the solution mechanically replicates the hand-folding process, with consistent precision and quality that would be difficult to achieve by hand. Since the technology can be applied to a range of commercially available paperboard grades, it requires no changes in the materials used.
Demo packages made from the FOLD material were showcased at the 2023 Design Weeks in Finland and the Netherlands. The goal for the future is to expand the technology’s applicable usage to other materials and find partners across Europe for pilot projects, as well as global partners for the commercialization phase after FOLD2’s completion.
This summer, VTT announced an initiative to develop low-carbon, water-efficient technology for fibre-based products. Said to have the potential to reduce water consumption by up to 90% and overall energy consumption by more than half, the initiative aims to address the challenges of energy and resource consumption in the forestry and textile industry.
More recently, Paptic revealed its recyclable, wood fibre-based material for feminine care products, seeking to deliver a ‘soft and pleasant’ user experience while reducing flexible plastic waste. The material is apparently designed for resource efficiency and can be recycled in the same streams as paper and cardboard.