Dufaylite Design Lab: Episode 2

Ultra Board desk build: Recyclable furniture for events, retail and exhibitions

The Ultra Board Desk Build is a practical demonstration of how recyclable furniture can be created quickly and cleanly using FSC® certified paper honeycomb board. Designed for real-world performance, this workstation build proves that eco-friendly exhibition desks can be lightweight, load-bearing, and easy to assemble without tools, glue, or plastic waste.

For printers developing temporary event workstations, showroom setups or sustainable POS furniture, this project demonstrates how sustainable display materials can be transformed into practical solutions for temporary home working, office fit-outs and spatial mock-ups.

Watch the Ultra Board desk build

Want to see the strength for yourself?

Looking to ‘bee’ inspired by what Ultra Board can really do?

Request a free bee-shaped sample made from the same recyclable board used in the Ultra Board Desk Build – a fully functional recyclable desk. Lightweight, printable and structurally strong, it’s the easiest way to experience our paper honeycomb board furniture material before your next campaign.

Don’t file this under “interesting” – fill in the form and we’ll send your sample straight to your studio.

How to create recyclable furniture using display board

Could flat-pack recyclable furniture, including a fully functional recyclable desk, made from display board really support real-world use in high-traffic environments? The Ultra Board Desk Build proves it can. Designed in the Dufaylite Design Lab using CAD modelling, rapid prototyping, and precision V-groove folding, this desk shows how printers can design and produce recyclable furniture, including a recyclable desk, from display board using only slot-fit construction techniques. The result is a scalable, print-ready solution for fast-turnaround installations, branded displays, and sustainable workspaces.

The Process

How the desk was built using recyclable display board

Slot-together design using CAD-cut components
V-grooves for folding without compromising strength
Integrated cable management feature
Smooth liner surface for direct print or wrapping
Built entirely from recyclable paper honeycomb board
Flat-packable for easy transport and reuse

From digital design to full assembly in under 10 minutes, this is a smart, sustainable solution for printers looking to expand into eco-friendly furniture builds.

The Result

Flat-pack recyclable workstations for print and POS

The Ultra Board Desk Build delivers what print teams need – strength, speed, and sustainability – all in one recyclable furniture unit.

No glue, screws or tools required
Assembles in minutes for fast-fit environments
Fully printable or brandable with wraps
Made entirely from recyclable materials
Perfect for exhibitions, retail setups or temporary offices

A clean, modern temporary workstation solution that’s strong enough for real tasks and light enough for agile installations.

Key benefits for printers creating recyclable furniture

Clean-cut, printable surface for high-quality branding
Lightweight for transport, strong enough for real-world use
Built entirely from recyclable paper honeycomb board
Fast, tool-free assembly using standard cutter workflows
Ideal for pop-up desks, retail backrooms or event control points
Helps printers deliver sustainable alternatives to plastic or PVC
Simple logistics for short-term projects, temporary workspaces and fast changeovers

The Ultra Board Range

Each Ultra Board grade is optimised for specific builds. For printers designing recyclable POS furniture, desks, signage or displays, choosing the right grade helps balance performance and cost.

3D and 3D White

Universal

Graphic

2D and 2D White

3D and 3D White

Best for structural furniture and large format POS.

Universal

Natural brown finish ideal for wrapped graphics.

Graphic

Lightweight and cost-effective for signage or budget displays.

2D and 2D White

Everyday eco boards for signage and mounting.

Compare Ultra Board Grades

Request a Free Sample ›

Frequently Asked Questions

Can Ultra Board be used to create recyclable desks for events and retail?

Yes. The Ultra Board Desk Build is a working example of how paper honeycomb board can be used to produce full-size, professional-looking 100% recyclable desks that are strong and lightweight. These desks are ideal for temporary installations at exhibitions, event control points, brand activations or pop-up retail zones. They provide a credible alternative to traditional furniture, delivering sustainability, clean design, and simple logistics in one package and can be placed into standard curbside recycling streams when no longer needed.

What makes Ultra Board a sustainable alternative for event desks?

Ultra Board is made from FSC® certified paper honeycomb board, making it one of the most sustainable options available for printers looking to reduce plastic and foam use. It contains no PVC, foam or glues and is fully recyclable after use. When used to build desks, it offers both performance and visual appeal, allowing printers to offer branded, eco-friendly exhibition desks that meet growing client demand for greener solutions in display and furniture builds.

Can the desk be printed or branded for campaign use?

Yes. Ultra Board is designed with a smooth surface that supports direct digital print or vinyl wrap finishes, making it perfect for branding. Whether you’re creating a workstation for a retail launch, a meet-and-greet table at a festival, or an information desk at an exhibition, this recyclable furniture can be fully customised with logos, messaging, colour palettes or campaign artwork. It helps elevate your client’s visibility while reinforcing their sustainability credentials.

How long does it take to assemble the Ultra Board desk?

Assembly is fast and can be done by a single person in under 10 minutes. The design uses interlocking panels and V-groove folds that allow the unit to fold, lock, and hold together securely all without glue or screws. For printers setting up temporary event workstations, this is a major time-saver and ideal for projects where last-minute builds or quick changeovers are required.

Is the Ultra Board desk strong enough for real use?

Absolutely. The Ultra Board Desk Build has been tested for load-bearing strength and successfully supports full adult use. Reinforced panels and the internal honeycomb structure give it surprising rigidity, making it a dependable solution for short-term use in retail environments, press offices, demo zones, or back-of-house setups. It’s a smart way for printers to offer recyclable POS furniture that looks professional and performs reliably.

Where are recyclable desks typically used in print-led projects?

Ultra Board desks are used by printers to create lightweight, flat-pack workstations for a range of temporary and modular environments. In addition to exhibitions and retail installations, they are commonly used in temporary home working setups, office fit-outs and spatial mock-ups, where sustainable, easy-to-assemble furniture is required.

Because paper honeycomb board combines structural strength with low weight and full recyclability, printers can produce desks that are simple to transport, quick to install and easy to dispose of responsibly after use, making them ideal for short-term projects and evolving workspace layouts.

Explore more recyclable furniture in the Dufaylite Design Lab

The Ultra Board Desk Build is just one of many innovative projects developed in the Dufaylite Design Lab. Each build shows how paper honeycomb board can be engineered into fully functional, brandable and recyclable display solutions made for printers who value strength, sustainability and speed. From seating to signage, these builds push the limits of sustainable display materials and showcase how flat sheet board becomes impactful, structural furniture.

Discover what’s possible with recyclable display furniture