Dufaylite Design Lab: Episode 1

Ultra Board chair build: Sustainable design solutions for printers

The Ultra Board chair build began with a simple question: what happens when Ultra Board is pushed to its creative limits? In the Dufaylite Design Lab, a CAD table, a clever structural design, and a slightly risky idea came together to turn a “what if?” moment into a surprisingly comfortable chair.

This build is a fully functional example of sustainable design solutions for printers, made entirely from 100% recyclable paper honeycomb board. It demonstrates how print-ready sustainable display materials can go far beyond signage. With no screws, no glue and no waste, it proves that eco-friendly POS boards can be both strong and practical, even as recyclable branded seating.

Typical applications for Ultra Board chairs include festivals and parties, office layout mock-ups, temporary home working environments and community events.

Watch the Ultra Board chair build

Ready to sit on a brilliant idea?

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

Request a free bee-shaped Ultra Board sample – the same recyclable, FSC-certified display board used in the Ultra Board chair build. It’s strong, lightweight, and beautifully printable, proving that even branded seating can be sustainable.

Don’t ‘bee’ left out – fill in the form opposite and we’ll send your sample your way!

How to build recyclable branded seating using display board

The Ultra Board chair build challenges the assumption that display boards are limited to flat, 2D graphics. Starting with a single flat sheet and a simple question – could a fully recyclable board become a chair that’s strong enough to sit on, smart enough to print on, and easy to assemble without glue or tools – the project set out to push the boundaries of sustainable display materials. Developed in the Dufaylite Design Lab, the solution combined CAD-led design with precision cutting, v-grooves for foldable strength, and slot-together engineering. The result is a fully functional chair made from paper honeycomb board, engineered to be lightweight, strong and completely plastic-free. Designed specifically with printers in mind, the build demonstrates how sustainable display substrates can be engineered into stable, branded seating for exhibitions, events and in-store environments, while also supporting flexible use in festivals, office layout mock-ups, temporary home working setups and community events. With no tools, adhesives or waste required, it’s ideal for fast-turnaround campaigns, modular POS and reusable display systems. For print teams looking to move beyond foam board or plastic-based furniture, the Ultra Board chair is a practical, real-world example of what’s possible when structural creativity meets recyclable materials.

The Process

How the chair was built from recyclable display board

CAD-cutting for precision slot-fit joins that allow fast, accurate assembly without hand tools
V-groove folding to create crisp edges and add strength without using glue or fasteners
Slot-together design that assembles entirely tool-free and flat-packs for efficient storage
Smooth liner surface that’s ideal for direct-to-board printing or wrapped branded graphics
Built from 100% paper honeycomb board to keep the structure lightweight, plastic-free and fully recyclable

The Result

Practical furniture built from recyclable materials

Lightweight and easy to transport, ideal for exhibitions, pop-ups, or retail environments, festivals and temporary event spaces
Strong enough to support a full-sized adult, proving paper honeycomb board is more than display-only
Fully recyclable and plastic-free, helping printers meet sustainability targets without compromise
Flat-packed and fast to assemble, saving time during event setups or in-store campaign
Comfortable enough for real-world use, combining structural integrity with a smooth, sit-friendly design
Significantly lighter than timber or conventional rigid boards, without compromising strength

A fully functional chair made from display board. Designed to surprise. Engineered for print.

Sustainable design solutions for printers

The chair build is just one example of sustainable design solutions for printers and what’s possible when sustainable display materials meet smart design. For printers, Ultra Board opens up a wide range of possibilities, not just for eco signage, but for full structural display solutions that are lightweight, printable, and plastic-free. From modular exhibition furniture to branded window displays and retail POS, Ultra Board enables 3D builds that combine creativity with commercial practicality. And because it cuts cleanly, assembles easily, and accepts direct print beautifully, it fits seamlessly into print production environments. Designed with sustainability at its core, Ultra Board helps printers offer clients innovative, high-impact alternatives to foam board, PVC, or plastic substrates without compromising on quality or visual impact.

Key benefits for printers

Easy to cut, crease, and print – no splinters or stress
Strong enough for structural builds, light enough for handling
100% recyclable and made from paper honeycomb board
Ideal for rapid prototyping, event furniture, POS and display units
Lightweight for easy handling and installation
A sustainable paper-based alternative to timber structures

The Ultra Board chair build is just one of many examples showing how recyclable display materials can be used to create eye-catching, functional solutions that stand up, literally to the demands of modern print and display environments.

The Ultra Board range

With multiple grades available, printers can select the most effective Ultra Board for each job – whether it’s building structural POS, developing prototypes, or creating sustainable display campaigns. Each board in the range is engineered to deliver strength, versatility and printability, while helping printers transition away from plastic substrates.

Universal

Graphic

3D and 3D White

2D and 2D White

Universal

Natural brown finish, ideal for wrapped graphics, rustic displays, and sustainable packaging.

Graphic

Lightweight and cost-effective, perfect for large-format printed panels and signage.

3D and 3D White

High-strength options with clean-cut edges, designed for bold, structural builds and display furniture.

2D and 2D White

Everyday eco signage boards, perfect for mounting prints or creating low-profile POS.

Whether it’s a complex installation or a quick-turnaround display, there’s an Ultra Board grade designed to meet the needs of printers seeking sustainable, recyclable alternatives.

Compare Ultra Board Grades

Request a Free Sample ›

Frequently Asked Questions

What is the best sustainable material for recyclable display furniture?

Paper honeycomb board is widely recognised as one of the best sustainable display materials for printers producing recyclable display furniture. It offers a rare combination of lightweight handling, structural strength, and smooth, printable surfaces. Because it is made entirely from recycled paper and is fully recyclable itself, it allows printers to deliver high-impact furniture and POS builds without relying on plastics, foams or composite substrates. Whether used for temporary seating, exhibition stands or in-store displays, it delivers on strength, sustainability and brand presentation. Compared with timber or traditional rigid boards, it offers a lighter-weight, fully recyclable alternative with excellent structural performance.

How can printers create slot-together displays without glue?

Printers can create slot-together displays by using CAD-cut designs on materials like paper honeycomb board. This board is particularly well-suited for glue-free builds thanks to its strength, foldability and internal cell structure. By incorporating v-grooves and interlocking tabs directly into the design, printers can build lightweight furniture, POS units and signage that assembles quickly and cleanly without screws, adhesives or tools. The Ultra Board chair build is a prime example of how this technique works in practice, showing how paper honeycomb can be engineered into fully functional, flat-pack seating that meets both creative and sustainability goals.

What is the best board for rapid prototyping sustainable POS?

Paper honeycomb display board is one of the most effective substrates for rapid prototyping in sustainable POS design. Printers can cut, fold and assemble the material easily using standard CAD tools, allowing for fast iteration and real-world testing of structural or visual concepts. Because the board is recyclable, prototypes can be created without waste, and once approved, the same material can be used for the full production run. It is also suitable for prototyping recyclable branded seating and other structural displays, making it ideal for time-sensitive campaigns, short runs and modular display units.

What is the best sustainable alternative to foam board for wide-format printing?

For printers looking to move away from foam PVC and plastic composites, paper honeycomb board is the best high-performing sustainable alternative. It offers a similar level of rigidity and surface smoothness, making it suitable for wide-format printing but without the environmental drawbacks of traditional foam boards. As part of a growing range of sustainable design solutions, it is easy to cut, does not crack or flake, and is made from recycled paper, making it fully recyclable and easier to dispose of responsibly via curbside recycling. Whether used for signage, mounting or 3D display builds, it provides a practical and eco-conscious replacement that aligns with modern sustainability goals.

Can printers print directly onto recyclable display board?

Yes. Most recyclable honeycomb display boards feature a smooth liner surface that is optimised for direct-to-board printing using UV, latex or solvent inks. Printers can achieve sharp, high-definition results suitable for branded retail displays, exhibitions or custom furniture. This eliminates the need for mounting additional substrates, saving time in production and reducing waste. The board’s compatibility with flatbed printers and digital workflows makes it a versatile and sustainable display material choice for modern print environments.

Watch the Ultra Board chair build

See how the Ultra Board chair build was brought to life in the Dufaylite Design Lab. In this short video, Managing Director Ashley walks through the build process and puts the finished chair to the test. It’s a practical demonstration of how paper honeycomb board can be used to create strong, recyclable furniture without glue, screws or waste, with a few laughs along the way!

Watch the Ultra Board chair build

Enter the Virtual Dufaylite Design Lab

For printers looking to push sustainable materials further, the Dufaylite Design Lab offers a practical look at what is possible with Ultra Board. From chairs and desks to beds, banners and retail displays, each project transforms paper honeycomb board into real, structural builds designed for professional print environments. The Ultra Board chair build is just the beginning. These video builds demonstrate how recyclable display materials can be engineered into modular furniture, 3D POS units and branded installations without plastic, glue or waste. It’s where structural integrity meets creative freedom, backed by materials that help printers meet sustainability goals.

Explore the builds. See the results. Discover how Ultra Board performs in real-world applications for print and display.