Finnish origami technology reinvents cardboard packaging

This continuous reel-to-reel process creates lightweight, durable and visually appealing packaging materials, which offer a sustainable alternative to plastics and expanded polystyrene.

The technology was developed as part of the FOLD and FOLD2 projects to address growing concerns over the environmental impact of traditional packaging. The global rise of e-commerce has increased demand for protective materials, while sustainability issues like microplastic pollution push industries to seek greener solutions. 

“The technology of FOLD is completely unique in the world,” said Jarmo Kouko, the FOLD project’s creator 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.”

The innovative approach replicates intricate hand-folding techniques mechanically, achieving consistent precision and quality. The researchers chose to use the Japanese Miura origami pattern, which is relatively simple and potentially suitable for folding many other materials, such as felt or polyethylene terephthalate (PET) film.

The technology can also work with recycled materials, noted Kouko.

Industrial collaboration

The two-phased FOLD project has involved 13 companies, universities and organisations working to expand cardboard’s potential as a packaging material. The project initially focused on designing a machine to fold origami cardboard. The second phase, FOLD2, began in March 2024 and is currently testing additional materials for similar applications.

According to Jari Räsänen, R&D manager at Stora Enso, the close partnership between researchers and industry could see origami cardboard reaching the market within three to five years. 

“The packaging industry is very interested in FOLD, and co-operation with enterprises enables us to move quickly from innovation to practical application,” he explained.

Beyond its environmental and functional benefits, the technology has also drawn interest from designers. The researchers showcased demo packages made from origami cardboard at designs weeks in Finland and the Netherlands and received positive feedback. 

The technology is particularly promising for luxury packaging, such as in the cosmetics industry, where design plays a major role in the consumer experience. It also has potential applications for the food industry, a sector where Finnish companies have already gained a reputation as innovators.

Furthermore, the FOLD project’s multidisciplinary nature has led to new research opportunities.

“This project demonstrates the power of collaboration,” said Kirsi Peltonen, a mathematics lecturer at Aalto University. “Its results are not only applicable to packaging but also to interior structures and abrasive products.”

The research team’s future goal is to expand the technology’s applications to other materials and to find European partners for pilot projects, as well as global partners for the commercialisation phase, after FOLD2’s completion. 

In addition to VTT and Aalto University, the project has involved Anpap, Business Finland, Elomatic, Lumene, Marja-Suomen Taimituotanto, Metsä Board, Mirka, Orfer, Soften, Stora Enso and Walki.