Strong, Lightweight, and Carbon-Storing: Hollow Wooden Profiles for Industry

A series of German research projects is opening new opportunities for wood in industrial applications. These range from construction and interiors to automotive and product design. Hollow wooden profiles—lightweight, material-efficient, and strong—are now being developed through innovative manufacturing techniques. They offer a sustainable alternative to steel, aluminium, and plastics.

A Sustainable Material with High Potential

Wood from domestic forestry or agroforestry requires little energy to harvest and process. It stores carbon throughout its life cycle and can be reused for renewable energy at the end of service. By replacing energy-intensive materials, engineered wood products can lower CO₂ emissions and support regional economies. As a result, they are increasingly relevant for sustainable design.

Innovative Manufacturing Approaches

Researchers at TU Dresden created hollow profiles from machine-braided veneer strips made of natural beech and birch. The profiles are surface-impregnated with a biobased epoxy resin. They match the mechanical performance of glass-fibre reinforced plastics. In addition, the method enables automated production and allows both round and angular cross-sections, which expands design freedom.

The University of Kassel and partners are developing woven tubes up to 40 cm in diameter from continuous willow yarn. Willow offers excellent bending elasticity, tensile strength, and low weight. Therefore, willow textiles show strong potential for decorative interiors and technical composite applications.

TU Dresden and GHEbavaria are producing hollow profiles from solid wood bent across the grain. This is new for the construction sector. The technique uses material efficiently, works with many domestic wood species, and integrates well with fibre-reinforced composites. Moreover, it broadens both design and engineering options.

Niemeier Fahrzeugwerke and its partners developed a process to extrude high-strength tubular profiles from compressed spruce rods. Fibre reinforcement with glass, carbon, or aramid improves strength and prevents deformation. These tubes are light, damp vibrations, and can replace certain steel structures.

The Ostfalia University of Applied Sciences improved solid wood bushings for use in friction-heavy parts such as bearings and seals. They achieved this through densification, heat treatment, and wax impregnation. As a result, the components outperform ultra-high-molecular-weight polyethylene (UHMWPE) without releasing microplastics or toxic emissions.

Applications Across Design Disciplines

These innovations create opportunities for architects, product designers, automotive engineers, and interior specialists. Designers can integrate lightweight, high-performance, and bio-based elements into load-bearing frames, modular interiors, or composite automotive parts. In this way, hollow wooden profiles combine strength, sustainability, and design flexibility.

Source: Fachagentur Nachwachsende Rohstoffe (FNR)
Photos: Universität Kassel / TU Dresden / Tom-Egmont Werner / Niemeier Fahrzeugwerke / O. Waßmann