A team of Finnish researchers has developed a groundbreaking technology that uses origami-inspired folding techniques to create sustainable, fiber-based packaging materials.
Led by the VTT Technical Research Center of Finland and Aalto University, this innovation transforms cardboard into lightweight, durable, and visually appealing packaging, offering an eco-friendly alternative to traditional materials like plastic and polystyrene.
The origami folds give cardboard new properties, such as greater strength and flexibility, without adding extra weight.
These qualities make it ideal for protective packaging and open up exciting design possibilities.
This unique material has already caught the eye of designers for its beautiful appearance and potential to replace less sustainable options in industries like e-commerce, food, and cosmetics.
The demand for sustainable packaging is growing, as concerns about the environmental impact of materials like plastic increase. Issues such as microplastic pollution and the carbon footprint of traditional packaging have made the search for better alternatives more urgent.
The FOLD and FOLD2 projects, which involve 13 organizations and companies, are part of this effort. They aim to rethink how cardboard is used in packaging and to develop new materials and processes to meet the challenges of modern industries.
The FOLD project began by designing a machine that can fold cardboard using origami techniques.
While origami is traditionally done by hand, this process has been adapted for industrial use. The new machine replicates the complex folding patterns with consistent precision, making it possible to mass-produce folded cardboard on a large scale.
The Japanese Miura fold, a relatively simple origami pattern, was chosen for its suitability for commercial use.
This folding method can also be applied to other materials, such as recycled paper, aluminum foil, or plastic films like PET. This flexibility means the technology could be used for many types of packaging in the future.
The FOLD project is a collaboration between researchers, universities, and eight industrial companies.
The next phase, called FOLD2, started in March 2024 and focuses on testing additional materials and expanding the technology’s applications. The goal is to bring the technology to market within the next three to five years, with pilot projects planned across Europe and beyond.
Jari Räsänen, R&D Manager at Stora Enso, one of the companies involved, says, “The packaging industry is very interested in FOLD. With strong partnerships, we can move quickly from innovation to practical applications.”
In addition to its functional benefits, the folded cardboard has inspired designers. Demo packages made from the material have already been showcased at design events in Finland and the Netherlands, receiving positive feedback. The material is particularly appealing for luxury packaging, such as cosmetics, where the unboxing experience matters to consumers.
“Origami’s visual appeal and renewable materials are perfect for consumer products,” says Essi Arola from Lumene, a Nordic skincare company.
The FOLD project is a shining example of teamwork across disciplines. Mathematicians, engineers, and designers worked together to solve the challenges of folding and create practical solutions for real-world use.
“This project combines geometry, materials science, and engineering to create something entirely new,” says Aalto University’s mathematics lecturer, Kirsi Peltonen. “The results aren’t just for packaging—they could also be used in abrasives or interior design.”
With its potential to reduce plastic waste and improve packaging sustainability, origami-inspired cardboard could transform the way we think about packaging in the years to come.
