A new technology developed by VTT Technical Research Centre of Finland, in collaboration with Aalto University and several industrial partners, promises to transform the packaging industry with sustainable, lightweight, and visually appealing materials inspired by origami.
The innovation uses a continuous reel-to-reel process to fold cardboard into intricate, durable structures that can replace conventional materials such as plastic and expanded polystyrene. Beyond functionality, the technology has caught the attention of designers, highlighting its potential in luxury and consumer goods packaging.
As e-commerce expands, so does the demand for packaging materials with lower environmental impact. Addressing concerns like microplastic pollution, the FOLD and FOLD2 projects have pioneered a process that not only enhances cardboard's versatility but also integrates recycled materials.
"The technology is globally unique," said Jarmo Kouko, leader of the FOLD project at VTT. "It transforms cardboard into a flexible and protective material while maintaining aesthetic appeal, with applications ranging from consumer packaging to industrial uses."
Inspired by traditional origami, the process replicates intricate folding patterns with mechanical precision, ensuring scalability and consistency. The Miura fold, chosen for its simplicity and adaptability, can be applied to other materials such as PET films and aluminum foil, broadening its application scope.
Industry Collaboration Accelerates Market Readiness
With support from eight industrial partners, including Stora Enso and Lumene, the FOLD2 project launched in March 2024 to refine the technology and explore new materials. According to Jari Räsänen, R&D Manager at Stora Enso, the project could see origami-inspired packaging enter the market within three to five years.
"Collaboration with companies enables swift progression from innovation to practical application," Räsänen noted.
Designers Embrace the Aesthetic Potential
The technology’s aesthetic appeal has made waves in design circles, with demo packaging showcased at major events like Design Weeks in Finland and the Netherlands. Companies in the luxury goods and cosmetics sectors, such as Lumene, see potential in offering environmentally conscious yet visually striking packaging options.
"The renewable material and unique appearance of origami make it ideal for premium consumer products," said Essi Arola of Lumene.
A Multidisciplinary Breakthrough
Beyond packaging, the project has sparked interest in diverse applications, from interior design to abrasive materials. Kirsi Peltonen, a mathematics lecturer at Aalto University, highlighted the collaboration’s interdisciplinary nature, combining geometry, engineering, and materials science.
With the FOLD project paving the way for sustainable innovation, its success underscores the potential of multidisciplinary efforts to redefine industries.
VTT Technical Research Centre of Finland Ltd is a leading research, development, and innovation partner with over 80 years of experience. VTT combines cutting-edge science and technology to drive sustainable growth, tackle global challenges, and create business opportunities. By bridging innovation and industry, VTT helps companies and society transform ideas into impactful solutions that advance both sustainability and competitiveness.
