VTT Technical Research Centre of Finland, in collaboration with Aalto University and several Finnish industrial partners, has developed a new packaging material inspired by origami. The technology enables a continuous reel-to-reel folding process for fibre-based cardboard, creating lightweight, durable, and visually distinct packaging. This development offers a sustainable alternative to traditional materials such as plastic and expanded polystyrene. Its properties make it particularly relevant for designers in packaging, product development, and interior applications.

Advancing Material Functionality Through Folding
The FOLD and FOLD2 projects, involving 13 organisations, focus on rethinking cardboard’s potential as a packaging material. The folding process is mechanically precise, transforming flat materials into three-dimensional structures with enhanced flexibility and durability. The technology is compatible with various commercially available paperboard grades, requiring no material changes to integrate into existing production systems.

“The origami-inspired folding creates a material that is protective, lightweight, and visually appealing while also being scalable for industrial production,” says Jarmo Kouko, Research Team Leader at VTT and originator of the project. The technology also supports the use of recycled paperboard, contributing to circular economy goals.

The Miura fold pattern, selected for its efficiency, has proven adaptable for other materials in preliminary tests, including plastic films, aluminium foil, and felt. This flexibility suggests a range of potential applications beyond packaging.

Applications Across Design Disciplines
While the primary focus of the project is packaging, the material’s design and structural characteristics have drawn interest from other sectors. Demonstrations at design events have highlighted its potential for luxury goods packaging, food packaging, and decorative or functional interior panels.

Kirsi Peltonen, a mathematics lecturer at Aalto University involved in the project, notes the multidisciplinary nature of the research: “Understanding geometric folding structures, materials science, and engineering has enabled both practical applications and new research directions.”

Sustainability and Market Readiness
The development aligns with increasing demand for sustainable materials in design. By enabling the use of recycled materials and reducing the need for less sustainable options like plastic, the technology supports environmental goals. Additionally, the material’s light weight could reduce transportation emissions, enhancing its sustainability credentials.

In the FOLD2 phase, the focus is on expanding the range of compatible materials and preparing for commercialisation. Industry partners, including Walki Group and Stora Enso, are exploring applications for consumer goods and fibre-based food packaging. The technology is expected to enter the market within 3–5 years.

Broader Implications for Design and Industry
The origami-inspired material demonstrates how innovations in folding techniques can enhance material functionality and aesthetics. While primarily aimed at packaging, its adaptability and sustainability have implications for a wide range of design disciplines.

Source: VTT Technical Research Centre of Finland
Photos: VTT Technical Research Centre of Finland