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If you’re exploring packaging solutions that marry low weight with high durability, honeycomb paperboard for product displays delivers on both fronts. In sectors like automotive and electronics where every gram counts, this structured board protects your sensitive parts without the bulk of traditional materials. You’ll see how shedding as little as 10 percent of packaging weight can boost fuel efficiency by 6 to 8 percent in transport, trimming costs and carbon emissions in one move.
This article walks you through the core benefits of honeycomb paperboard, from its unique cell-based structure to real-world performance comparisons against solid boards. You’ll learn how to design, test, and implement this material in your next display project, plus practical tips for working with suppliers. If you want to reduce freight charges, minimize damage risk, and showcase your products in a lean, sustainable way, read on.
Honeycomb paperboard consists of a paper or kraft liner sandwiching a honeycomb-shaped core, creating a high strength-to-weight ratio. You’ll find two main layers:
The core’s hexagonal cells mimic natural honeycomb, distributing forces evenly and preventing point failures. Typical materials include recycled kraft paper or high-grade liners bonded with water-based adhesives. You can adjust cell size (e.g., 6 mm to 50 mm) to tune stiffness and cushioning to your needs.
This process keeps waste low and allows for customizable panel thickness from 10 mm up to 100 mm or more. If you need inspiration beyond displays, explore our piece on honeycomb paperboard packaging.
Weight reduction is often your top KPI. By switching to honeycomb paperboard for product displays, you can:
A typical solid-board display frame may weigh 1.5 kg, while a honeycomb version of equal dimensions can tip the scale at just 0.5 kg. Over a production run of 1,000 units, that’s a 1,000 kg saving.
Trimming 10 percent off your loaded weight can boost vehicle fuel efficiency by 6 to 8 percent. In a fleet moving electronics modules daily, that efficiency gain translates to five-figure annual savings on fuel alone and a smaller carbon footprint for your logistics.
Despite its lightness, honeycomb paperboard holds up under stress. You’ll appreciate its consistency in both static and dynamic loads.
Hexagonal cells absorb and dissipate shock energy. A drop-test comparison showed honeycomb panels matched solid boards in preventing chassis or circuit damage—yet weighed far less.
Compression tests reveal a honeycomb panel can support several hundred kilograms per square meter before buckling, depending on cell size and liner grade. You can fine-tune specs for shelves, risers, or full display structures.
Before you commit, it helps to see a side-by-side comparison.
| feature | honeycomb paperboard | solid fiberboard |
|---|---|---|
| weight | 30–70% lower | baseline |
| impact resistance | high, due to energy dispersion | high |
| compression strength | 200–600 kPa | 300–700 kPa |
| cost per sq m | moderate, scales with volume | lower at small runs |
| recyclability | curbside recyclable | curbside recyclable |
You’ll notice honeycomb matches or exceeds the protective qualities you need, with a significant weight edge.
While unit cost may be slightly higher for small runs, the total delivered cost often comes out ahead.
If shipping adds \$0.50 per kg, your break-even point may occur in runs as small as 500 units when you factor in reduced freight charges.
Consider shorter assembly times, fewer damage claims, and lower transport fees. Over a product lifecycle, these savings compound, often outpacing any up-front material premium.
Sustainability is nonnegotiable in your industry. Honeycomb paperboard helps you deliver on green goals.
Made primarily from recycled fibers, this board is curbside recyclable and compostable in many regions. Production yields less scrap than die-cut solid boards, minimizing landfill contributions.
A cradle-to-gate study shows honeycomb paperboard’s carbon footprint can be up to 25 percent lower than foam-based alternatives. By choosing paper-based solutions, you cut embodied carbon and support circular economies.
You’re not limited to flat panels. Honeycomb configurations open up creative display options.
Laser-cutting or CNC routing creates bespoke geometries—angled shelves, branded cutouts, or multi-tier risers—with minimal tooling cost.
Linerboards take ink, foil, and UV coatings well. You can achieve high-contrast graphics, tactile finishes, or spot varnish accents to match brand guidelines.
Ready to act? Follow these steps:
Maintain quality by tracking a few key metrics.
Conduct quarterly drop tests and compression trials. Record hysteresis data to ensure your displays keep performing through multiple retails cycles.
You’ve seen the potential, now make it real.
Run a limited production of your top display design. Measure weight, strength, and user response. Compare to your existing solution in a side-by-side showcase.
Once you validate performance, negotiate volume pricing with your supplier. Update CAD files, finalize print artwork, and prepare for full launch.
By adopting honeycomb paperboard for product displays, you’ll deliver lighter, greener, and more durable packaging that elevates both your products and your brand.