Corrugated Fiberboard Creations

by Yun-Han Lin

1. Knowing the material

Corrugated fiberboard is a common material for paper boxes for packaging. It is lighter than wooden ones, yet hard enough to protect the packaged products, and easy to be cut into different sizes. In addition, they can be printed or written with different color, patterns, and texts on the outside, and the cost is relatively low.

They are also used as a crafting material and are available in a variety of colors. Most corrugated boards feature wavy structure in the inner layer, which adds to the board strength and serves as a buffering. The more layers, the stronger the board, which is divided into various types according to thickness:

corrugated board

Honeycomb Board

Many manufacturers have developed and changed the wave structure in the inner layer into cross-mesh pattern or honeycomb pattern to add to the board integrity, so that the boards can be used in different furniture pieces.

2. Three-dimensional models

Compared with other materials such as wood, corrugated board is easier to obtain and processed, which make a good material for DIY enthusiasts or students for their art projects.

  1. Fixation of L-shaped brace
    1. Fold
    1. L Brace: L-shaped corner brace fixed with tape
    1. Gusset Brace: small cardboard pieces placed in the corner to strengthen support
    1. Rod Brace: bamboo sticks placed in the corner to strengthen support
    1. Tabs- symmetrical feet for support
    1. Foot- crossover feet for support

2. Cross structure

2-1. X-slot: a common structure to assemble several pieces of cardboard to form warp and weft as a solid three-dimensional structure

2-2. Insert

3. Patching

3-1. Wrap (X-bundle)

3-2. Cross lacing (X-bundle)

4. Movable

4-1. Brad: using brads or screws

4-2. Hinges: split pin with wire

4-3. Hanging with wire

5. Columnar structure

5-1. Flange: cylinder and standing feet, with hollow structure

5-2. Stacking: pieces stacked with paste to form solid construction

6. Bend

6-1. Smooth bend: better to be bent in the direction perpendicular to the wave inner layer of the board

6-2. Scored bend: with a larger bending angle

3. Corrugated board projects

1. FlexibleLove by Chishen Chiu.

Designer artist Chishen Chiu comes from Miaoli, Taiwan. Inspired by the honeycomb board, Chiu developes a layered model of corrugated board that can be stretched. When folded, it seems that only one person can fit in the chair, but it can actually hold ten people if popped open.


2. Chairigam, an American cardboard furniture brand founded by Zach Rothholz. Their furniture features three-layer walls of corrugated board. The structure is simple and easy to assemble and it has good integrity. People interested in cardboard furniture may find it intriguing.


3. ButterNmilk

Bartholomew T, also known as Bart, is an artist from Singapore. Bart uses thick cardboard to build huge projects. For instance, at 2019 Maker Faire Taipei at Songshan Cultural and Creative Park, Bart presented a 5- to 6-meter tall tyrannosaurus that was a hollow polyhedron, assembled with cardboard piece by piece.


4. Corrugated cardboard toy by Novice Workshop

Our workshop has also tried building automata projects using corrugated cardboard. The size was small, so we used 1.5 mm ~ 2 mm cardboard, which was thinner than usual. In the center was a crankshaft placed for movement, where the flower on the top of the cactus would be able to pop up and down upon movement.

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