Revolutionizing Packaging: Finland's Origami-Inspired Cardboard Technology
In a groundbreaking collaboration between VTT Technical Research Centre of Finland, Aalto University, and key Finnish industrial partners, a revolutionary innovation is transforming the packaging industry. The FOLD and FOLD2 projects have introduced a world-first continuous process for shaping cardboard into origami-inspired structures, offering a sustainable and visually stunning alternative to traditional packaging materials like plastic and expanded polystyrene.
A New Era for Cardboard
This cutting-edge technology turns ordinary cardboard into lightweight, durable, and visually appealing packaging, perfect for a range of applications. The intricate folds, inspired by the ancient art of origami, bring new properties to cardboard, making it an exceptional alternative for protective and decorative packaging solutions. Its environmental benefits and design potential are attracting widespread attention, from industrial manufacturers to luxury product designers.
“The technology of FOLD is completely unique in the world,” explains Jarmo Kouko, the creator of the FOLD project and Research Team Leader at VTT. “Origami folding transforms cardboard into a flexible, protective, and visually appealing material unlike anything that’s previously been available for industry-wide production. It even has the capacity to produce foldable materials from recycled goods.”
The innovation addresses growing concerns over the environmental impact of packaging, including issues like microplastic pollution. By offering a sustainable and scalable solution, the FOLD project is paving the way for greener, more efficient packaging practices.
The Science of Folding
Inspired by the precise art of hand-folded origami, Kouko and his team developed a mechanical process to replicate these intricate folds. The Miura folding pattern, chosen for its simplicity and versatility, ensures that materials retain their structural integrity while gaining new properties. The method requires no changes to existing paperboard grades, making it commercially viable and eco-friendly.
The technology’s adaptability is another standout feature. While cardboard is the primary focus, the team has begun testing other materials, such as aluminum foil, PET films, and even felt, with promising results.
Industry Collaboration Driving Change
The FOLD initiative represents a true partnership between academia and industry. Eight companies, including Stora Enso, Lumene, and Walki Group, contributed to the development and funding of the project. This collaboration ensures the swift transition from innovation to practical application, with plans for pilot projects across Europe and commercial rollout within the next five years.
“The packaging industry is very interested in FOLD,” says Jari Räsänen, R&D Manager at Stora Enso. “Close cooperation with enterprises allows us to move quickly from concept to market-ready solutions.”
Aesthetic Appeal Meets Functionality
The unique visual appeal of the origami cardboard has sparked interest among designers and luxury brands. Demonstrations of the material at design exhibitions in Finland and the Netherlands have garnered significant enthusiasm. For industries like cosmetics and high-end consumer goods, the material offers an elegant and sustainable alternative to conventional protective packaging.
“Origami works beautifully for consumer products,” notes Essi Arola from Nordic skincare company Lumene. “It combines aesthetic value with environmental consciousness, elevating the unboxing experience.”
Beyond Packaging
The potential applications for the origami-inspired material extend far beyond packaging. The technology opens doors to new research and innovations across multiple disciplines, from interior design to abrasive product manufacturing.
“This project is a testament to the power of multidisciplinary collaboration,” says Kirsi Peltonen, a mathematics lecturer at Aalto University specializing in origami. “The intersection of mathematics, materials science, and engineering has produced not only practical solutions but also exciting research opportunities.”
Towards a Sustainable Future
As the global demand for sustainable packaging grows, Finland’s origami cardboard innovation marks a significant step forward. By combining functionality, sustainability, and design, the FOLD project is setting a new standard in the packaging industry, aligning with global efforts to reduce waste and carbon footprints.
With the second phase, FOLD2, underway, the future of packaging looks increasingly bright—and green.
