Dufaylite Design Lab: Episode 4

Ultra Board bed build: Recyclable display furniture

The Ultra Board bed build demonstrates how recyclable display materials can be engineered into full-size, load-bearing furniture. Designed and built entirely from paper honeycomb board in the Dufaylite Design Lab, it shows printers what’s possible when sustainable display materials are pushed beyond signage and into structural form.

For printers responding to growing demand for eco alternatives to plastic and foam, this bed build provides a practical, real-world example. It proves that recyclable print substrates can deliver strength, stability and a professional finish, without glue, screws or waste. Unlike high-profile cardboard bed projects such as those used at the Olympics, which relied on multiple layers of corrugated board, Ultra Board achieves greater strength and simplicity through engineered paper honeycomb construction.

Watch the Ultra Board bed build

Want to test the strength for yourself?

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

See exactly what Ultra Board can handle by requesting a free bee-shaped sample made from the same fully recyclable, FSC® certified board used in the Ultra Board bed build. Lightweight, printable and seriously strong, it’s the ideal way to explore structural display materials before your next POS or event build.

Don’t sleep on it! Fill in the form opposite and we’ll send your sample straight to your studio.

How to build recyclable display furniture using Ultra Board

It began with a simple challenge. Could a fully recyclable display board support real-world weight while remaining printable, lightweight and easy to assemble? In the Dufaylite Design Lab, that challenge was answered through CAD-led design, structural testing and slot-together construction. The result is the Ultra Board bed build, a full-scale piece of display furniture made entirely from paper honeycomb board. For printers, it demonstrates how sustainable display materials can be used to create branded, functional furniture for exhibitions, retail environments and temporary installations, using sustainable display materials that help meet environmental targets. Compared with corrugated board builds, this approach delivers higher structural performance with fewer material layers and simpler construction.

The Process

How the bed was built from recyclable display board

To demonstrate the structural capabilities of recyclable display board, the Ultra Board Bed Build was engineered using a combination of CAD-led design and precision cutting techniques. The process focuses on strength, efficiency and sustainability showing printers how paper honeycomb board can be transformed into full-size, functional furniture without the need for glue, screws or tools.

CAD-designed components for precise slot-fit assembly 
V-grooves used to create clean folds and structural strength 
Internal cross-beam panels to distribute load evenly 
Glue-free and screw-free construction using interlocking parts 
Smooth liner surface suitable for direct print or wrapped graphics 
Built using high-strength paper honeycomb board for structural stability

This approach allows printers to move from flat sheet to full-size furniture using standard digital cutting equipment.

The Result

Recyclable display materials with real strength

The Ultra Board bed build proves how recyclable display materials can be engineered into full-scale, functional furniture for print-led environments. Designed for fast assembly, flat-pack efficiency and real-world performance, this solution redefines what paper-based substrates can achieve.

Strong enough to support two fully grown adults
Lightweight and easy to transport
Flat-pack design for efficient shipping and storage
Quick to assemble and dismantle without tools
Fully recyclable and plastic-free

A full-size bed built entirely from recyclable display board. Designed for print environments. Tested for real-world use.

Recyclable display furniture for exhibitions, retail and temporary spaces

The Ultra Board bed build shows how recyclable display furniture can be used in many environments where strength, speed and sustainability all matter. From exhibitions and retail pop-ups to temporary installations and showroom displays, this build highlights how printers can offer furniture-scale solutions using sustainable materials. For print teams, this is more than a prototype. It’s a blueprint for delivering modular display furniture, eco-led client campaigns and alternatives to foam board or plastic-based structures. Ideal applications include:

Exhibition stands and event furniture
Retail zones and in-store pop-ups
Temporary or emergency installations
Concept furniture and showroom displays
Print teams offering sustainable alternatives to plastic or foam

Key benefits of Ultra Board for printers

Clean-cut, printable surface for direct graphics or wrapped branding
Strong enough for structural builds, light enough to transport and assemble
100% recyclable and FSC certified
Ideal for prototyping, POS builds, modular display furniture and more
Higher strength-to-weight performance than many corrugated cardboard constructions
Simpler to design, cut and assemble than multi-layer corrugated builds

The Ultra Board bed build is one of many examples showing how recyclable display furniture can help printers reduce waste, expand service offerings and deliver impactful results with sustainable materials.

Choose the right Ultra Board for structural display furniture

Creating load-bearing display furniture requires the right board grade. The Ultra Board range gives printers flexibility depending on strength, finish and application.

3D and 3D White

Universal

Graphic

2D and 2D White

3D and 3D White

High-strength grades designed for structural furniture and large POS builds.

Universal

Natural brown board, ideal for wrapped graphics and eco-led displays.

Graphic

Lightweight and cost-effective for printed panels and signage.

2D and 2D White

Everyday eco signage and mounting solutions.

With Ultra Board, printers can design, prototype and produce recyclable display furniture without relying on plastic or foam substrates.

Compare Ultra Board Grades

Request a Free Sample ›

Frequently Asked Questions

What recyclable display materials are available for structural builds?

For printers, paper honeycomb display board is one of the most effective recyclable display materials for structural builds. Made from recycled paper and fully recyclable, it combines low environmental impact with the strength required for furniture-scale applications. It can be used for everything from flat signage to modular display furniture, helping printers meet sustainability targets without compromising print quality or build performance.

What is the best eco-friendly alternative to foam board for furniture-scale POS?

Paper honeycomb board is widely used as an eco-friendly, recyclable display board alternative to foam board and foam PVC. It delivers comparable rigidity and a smooth, printable surface without any plastic content. For printers producing branded furniture or 3D POS, it cuts cleanly, holds structural integrity, and supports load-bearing designs such as beds, sofas and platforms.

Can recyclable print substrates be used to build furniture for exhibitions or events?

Yes. Recyclable print substrates like paper honeycomb board have been used successfully to create full-size furniture for exhibitions, retail environments and temporary installations. These builds flat-pack for transport, assemble without glue or tools, and provide the strength needed for real-world use, making them ideal for event-led and modular display applications.

How do printers create slot-together display furniture without glue or fixings?

Printers create glue-free furniture by CAD-cutting interlocking components from paper honeycomb board. Slot-fit joints and V-grooves allow the structure to lock together securely without screws or adhesives. Builds like the Ultra Board Bed demonstrate how this approach works at scale, enabling fast, tool-free assembly with no plastic and minimal waste.

Can recyclable display furniture be printed or branded for client campaigns?

Yes. Paper honeycomb display board features a smooth liner surface that accepts direct-to-board print or wrapped graphics. This allows printers to produce fully branded, furniture-scale display builds for campaigns, events and retail zones, combining strong visual impact with recyclable materials and sustainable messaging.

Why should printers consider using sustainable display materials?

As sustainability becomes increasingly important across the print and display industry, printers are seeking materials that reduce environmental impact without compromising quality. FSC-certified paper honeycomb board is one of the most effective sustainable display materials available. It provides the strength, printability and versatility needed for modular furniture, structural POS and branded installations, all while supporting eco-conscious campaigns and client goals.

How does Ultra Board compare to corrugated cardboard in structural furniture builds?

Ultra Board differs from traditional corrugated cardboard by using an engineered paper honeycomb core rather than layered fluting. This allows printers to achieve greater structural strength with fewer layers of material, simpler construction and improved load-bearing performance.

While high-profile cardboard furniture projects, such as temporary beds built from corrugated board, often require complex multi-layer designs, Ultra Board enables printers to create strong, full-scale furniture using cleaner engineering, faster assembly and fully recyclable materials. This makes it a more practical solution for printers producing structural display furniture, event installations and branded builds.

Watch the Ultra Board bed build

See the Ultra Board bed build come together from flat sheet to full-size structure. This video shows how recyclable display board performs under real load and real-world conditions.

Watch the Ultra Board chair build

Enter the Virtual Dufaylite Design Lab

For printers exploring recyclable display furniture, the Ultra Board bed build is one example of what’s possible inside the Dufaylite Design Lab. Each project shows how paper honeycomb board can be engineered into functional, printable and sustainable display solutions.

Explore how printers are using recyclable materials to create furniture, POS displays and branded structures across a wide range of applications.