A groundbreaking origami-inspired packaging technology developed by Finland’s VTT Technical Research Centre, in collaboration with Aalto University and Finnish industrial partners, promises a sustainable alternative to conventional materials such as plastic and expanded polystyrene.
The innovation involves a continuous reel-to-reel process that shapes cardboard into intricate, flexible structures, combining lightweight durability with aesthetic appeal. This advancement offers a sustainable and visually striking option for protective packaging materials in industries such as e-commerce, food, and luxury goods.
The Fold Project: Revolutionizing Cardboard Packaging
The innovation stems from the FOLD and FOLD2 projects, involving 13 companies and institutions, with the first phase focused on designing machinery to create origami-inspired cardboard structures. These projects aim to redefine the use of fiber-based materials by making them flexible, protective, and highly customizable.
Jarmo Kouko, Research Team Leader at VTT and creator of the FOLD project, highlighted the unique nature of this technology:
“Origami folding transforms cardboard into a flexible, protective, and visually appealing material unlike anything previously available for industry-wide production. This technology also has the capacity to produce foldable materials from recycled goods.”
Inspired by traditional hand-folded origami techniques, the innovation uses mechanical processes to replicate intricate patterns with precision and consistency, eliminating the time constraints of manual folding. The technology is compatible with various commercially available paperboard grades without requiring changes to the base materials.
Broad Applications and Industry Interest
The origami technology has attracted significant interest from multiple industries, particularly for its sustainable qualities and versatility. During Finland and the Netherlands Design Weeks in 2023, demo packages crafted from the material were praised for their innovative aesthetics.
For example, the luxury cosmetics sector views FOLD as an opportunity to offer consumers an environmentally friendly yet premium unboxing experience. Essi Arola, a representative from Nordic skincare company Lumene, remarked:
“Due to its interesting visual appearance and renewable material, origami works well in consumer products.”
Annika Sundell from packaging firm Walki Group added:
“Folding cardboard opens up completely new possibilities for us when developing fiber-based packaging, particularly in the food industry.”
Expansion and Future Commercialization
Currently in its second phase, the FOLD2 project began in March 2024 with expanded testing for other materials, including recycled PET, aluminum foil, and molded pulp. Supported by a consortium of industrial partners, the project aims to scale the technology for broader commercial use across Europe and globally.
Jari Räsänen, R&D Manager at Stora Enso, emphasized the industry’s enthusiasm:
“Close cooperation with enterprises enables us to move quickly from innovation to practical application. We could see origami cardboard on the market within three to five years if the project progresses as planned.”
Multidisciplinary Collaboration
The success of the origami-inspired packaging technology highlights the power of interdisciplinary collaboration. From material science to mathematics and engineering, the project integrates diverse expertise to solve complex challenges.
Aalto University’s mathematics lecturer, Kirsi Peltonen, who specializes in origami, explained:
“This project is a good example of the power of multidisciplinary collaboration. In addition to packaging solutions, the results are also suitable for abrasive products and interior structures.”
A Sustainable Future for Packaging
As global demand for sustainable packaging rises, VTT’s origami technology offers an innovative solution that balances functionality, sustainability, and aesthetic appeal. With its potential applications spanning multiple industries, the FOLD project is set to redefine how cardboard and other materials are utilized, paving the way for a more eco-conscious future in packaging.
