The packaging materials market is expanding rapidly, fueled by the boom in e-commerce. However, there is an increasing focus on reducing the carbon footprint of packaging while also considering the materials’ composition. Global sustainability challenges, such as the environmental consequences of microplastic pollution, drive the demand for innovative and sustainable packaging solutions, particularly in the food and drink packaging sector.
Involving a diverse collaboration of 13 companies, organizations, and universities, the FOLD and FOLD2 projects represent critical initiatives aimed at transforming the utilization of cardboard as a packaging material. This two-phase project commenced with the design of a machine to fold origami cardboard, and is now shifting towards testing additional materials. The results have been overwhelmingly positive, leading to new applications for cardboard that are flexible, durable, versatile, and sustainable.
“The technology of FOLD is completely unique in the world. Origami folding transforms cardboard into a flexible, protective, and visually appealing material unlike anything that’s previously been available for industry-wide production. The technology we’ve developed also has the capacity to produce foldable materials from recycled goods,” asserts Jarmo Kouko, creator of the FOLD project and Research Team Leader at VTT.
Kouko’s inspiration stemmed from attending a packaging industry conference that explored various folding techniques. Traditionally, origami involves handcrafting intricate folds, a process that can take hours. While this labor-intensive method may limit commercial viability, Kouko envisioned a mechanical folding approach that could efficiently create lightweight, protective, and aesthetically striking forms.
The solution replicates hand-folding mechanisms mechanically, ensuring consistent precision and quality—an achievement challenging to realize manually. Importantly, the technology works seamlessly with a variety of commercially available paperboard grades, requiring no alterations to the materials used.
“The Japanese Miura origami pattern we’ve chosen is relatively simple, which makes it potentially suitable for folding many other materials. We have investigated the possibilities of developing techniques and models where felt or film made from PET, widely used in plastic packaging, could be shaped in the Miura form. We’ve also performed some preliminary testing for other materials, such as aluminium foil,” Kouko elaborates.
Industry Collaboration to Accelerate Commercialization
Eight industrial firms have actively participated in the FOLD project, contributing to both its development and funding. The current phase, known as FOLD2, began in March 2024, continuing to receive support from a consortium of companies. Our objective moving forward is to enhance the technology’s applicability, broaden experimentation with other materials, and forge partnerships throughout Europe for pilot projects, as well as globally for the commercialization phase post-FOLD2.
“The packaging industry is very interested in FOLD, and close cooperation with various enterprises enables us to move quickly from the innovation phase to practical application. We could see origami cardboard on the market within 3-5 years if the project progresses as planned,” notes Jari Räsänen, R&D Manager at Stora Enso, a collaborator on the project.
A Material that Inspires Designers
Beyond its functionality and eco-friendly attributes, the FOLD material also captivates designers. Demonstration packages derived from the origami cardboard have been displayed at the 2023 Design Weeks in Finland and the Netherlands, drawing considerable enthusiasm.
For instance, in luxury applications such as cosmetics, packaging aesthetics play a crucial role in the consumer experience. FOLD offers a premium unboxing experience that aligns with modern sustainability expectations, contrasting with conventional materials like plastic bubble wrap or expanded polystyrene.
“Due to its interesting visual appearance and renewable material, origami works well in consumer products,” states Essi Arola from Nordic skincare and cosmetics brand Lumene.
“Folding cardboard opens up completely new possibilities for us when developing fibre-based packaging, for example, for the food industry. With our new Japanese owner, origami folds are a particularly interesting topic,” adds Annika Sundell from packaging firm Walki Group.
The material also fosters innovative research and practical applications across various fields.
“This project is a good example of the power of multidisciplinary collaboration. Solving folding-related problems requires not only an understanding of the ideal geometric structures of mathematics but also knowledge of materials and modelling through design and engineering sciences. Unprejudiced hand-made prototyping has produced numerous new research questions alongside practical applications. In addition to packaging solutions, the project’s results are also suitable for, for example, abrasive products and interior structures,” summarizes Kirsi Peltonen, a mathematics lecturer at Aalto University specializing in origami.
Alongside VTT and Aalto University, the FOLD project has included Anpap, Business Finland, Elomatic, Lumene, Metsä Board, Mirka, Orfer, Soften, and Stora Enso. The FOLD2 initiative involves VTT, Aalto University, Anpap, Business Finland, Marja-Suomen Taimituotanto, Mirka, Soften, Stora Enso, and Walki.
For more detailed information, visit https://fold-project.com/
