Dufaylite Design Lab: Episode 5

Ultra Board curved POS build: Recyclable POS displays for retail, exhibitions and events

The Ultra Board curved POS build shows how recyclable display materials can be turned into strong, brandable point of sale displays — built entirely from FSC® certified paper honeycomb board. Designed for fast setup, clean print and seamless curved forms, this build gives printers a new way to deliver eco-friendly retail displays without relying on plastic or foam board. Lightweight, strong and fully recyclable, this display unit highlights how sustainable display materials can deliver creative structure, clean finish and real load-bearing strength for product displays, pop-ups and in-store promotions. It is particularly suited to displaying heavier products, such as drinks brands and multi-pack goods, that would normally require steel or timber POS units.

Watch the Ultra Board curved POS build

Want to try Ultra Board for POS builds?

See what Ultra Board can do by requesting a free bee-shaped sample — made from the same recyclable board used in the Ultra Board curved POS build. Lightweight, printable and plastic-free, it’s the perfect way to explore recyclable POS displays for retail, exhibition or product-led campaigns.

Don’t leave this one on the shelf — fill in the form and we’ll send your sample straight to your studio.

How to build curved display using recyclable POS materials

Creating curved POS units from recyclable board was once a challenge. But through slot-and-tab construction and advanced prototyping, the Dufaylite Design Lab shows printers how to achieve clean lines, structural strength and standout branding — all with paper honeycomb board. This Ultra Board curved POS build demonstrates how plastic-free retail displays can be prototyped, printed and assembled quickly for in-store use or temporary installations. Compared with corrugated board, Ultra Board is also ideal for shorter-run POS units, where high minimum order quantities and tooling costs would normally make production impractical. At the same time, it remains suitable for longer production runs, giving printers flexibility across campaign sizes.

The Process

How the curved POS unit was built using paper honeycomb board

Pre-cut shelf supports and curved back panels for clean lines
Vertical and lateral reinforcement for strong load capacity
Smooth liner surface for direct print or wrapped branding
Lightweight format for easy flat-packing and transport
Built entirely from sustainable display materials with no glue or fixings

This build allows printers to go from concept to branded, recyclable POS display in under 30 minutes using standard cutting equipment.

The Result

Recyclable POS displays built for print, strength and speed

The Ultra Board curved POS build proves that eco-friendly retail displays can deliver on print finish, structural performance and speed of setup.

Load-tested to hold multiple shelves of product
Fully printable surface for high-impact branding
Ideal for seasonal campaigns, brand activations and promotions
Built with no glue or screws for fast flat-pack assembly
Entirely plastic-free and 100% recyclable
Lightweight, strong and reusable across sites or clients

A practical POS display built for modern print workflows and sustainability goals.

Key benefits for printers creating recyclable POS displays

Rapid to assemble using digital cutting workflows
Clean, professional print surface for sharp retail graphics
Lightweight and easy to transport between events or stores
100% recyclable, made from FSC® certified paper honeycomb board POS
Durable enough for retail environments and event use
A smart alternative to foam PVC or plastic-heavy display units
Supports heavier loads without steel or timber
Stronger than many paper boards, lighter than rigid alternatives

Selecting the right Ultra Board for curved POS units

Whether you’re building curved POS displays or flat product stands, the Ultra Board range helps printers choose the right material for strength, finish and sustainability.

3D and 3D White

Universal

Graphic

2D and 2D White

3D and 3D White

Strongest for furniture-scale POS and display structures.

Universal

Natural brown board ideal for wrapped branding or eco messaging.

Graphic

Cost-effective board for printed panels and signage.

2D and 2D White

Slimline grades for basic display panels and mounting.

All boards are made from recyclable paper honeycomb and engineered for clean cutting and excellent print results.

Compare Ultra Board Grades

Request a Free Sample ›

Frequently Asked Questions

How can printers build curved POS displays using recyclable materials?

Printers can build curved POS displays using recyclable materials by working with paper honeycomb display board that is engineered for structural strength and controlled flexibility. In the Ultra Board curved POS build, curved forms are achieved through precision cutting, slot-and-tab assembly, and smart folding techniques rather than heat forming or plastic components. This allows printers to produce curved point of sale units that are lightweight, flat-packable and fully recyclable, while still delivering the visual impact and durability required for retail, exhibition and campaign environments.

Why is Ultra Board a practical choice for eco-friendly retail displays?

The Ultra Board curved POS build uses high-strength paper honeycomb board that’s lightweight, printable and fully recyclable, making it a strong example of sustainable display materials for eco-friendly retail displays. It cuts cleanly, holds shape under load and supports high-quality graphics, enabling printers to offer environmentally responsible POS solutions without compromising on finish or performance.

For printers looking to explore this in more detail, see our guide: Eco-friendly displays for printers: A practical guide to sustainable signage solutions.

Can recyclable POS displays be branded with full graphics?

Absolutely. Ultra Board features a smooth liner surface that supports high-quality direct digital printing as well as vinyl wraps, making it easy for printers to apply bold, detailed graphics across the entire POS unit. This allows each recyclable POS display to be fully customised for specific promotions, seasonal campaigns or retail partnerships. Combined with the structural strength of paper honeycomb board, printers can deliver eye-catching retail displays that balance visual impact, durability and recyclable substrates without compromising on print quality or finish.

Is the curved POS unit suitable for high-traffic or temporary retail spaces?

Yes. The Ultra Board curved POS build has been engineered to support real product weight while maintaining structural stability in busy retail environments. Designed for repeated use, it combines strength with a lightweight, flat-pack format that simplifies transport, storage and on-site handling. Quick to assemble without specialist tools, the unit is well suited to pop-up shops, touring brand activations and short-term in-store promotions, where speed, durability and presentation are equally important.

How does Ultra Board compare to foam board or plastic in POS builds?

Unlike foam PVC or plastic panels, Ultra Board is made from FSC® certified paper honeycomb and is fully recyclable through standard curbside recycling processes. It offers comparable rigidity and strength for POS displays, but with a significantly lower environmental footprint. For printers, this means being able to offer clients a high-quality POS solution with clear, credible sustainability credentials.

Explore more recyclable display furniture in the Dufaylite Design Lab

The Ultra Board curved POS build is just one of many projects developed in the Dufaylite Design Lab to help printers rethink what’s possible with recyclable display materials. From seating and storage to structural signage and retail displays, these builds demonstrate how printers can turn flat board into durable, high-impact solutions for real-world use.

See More from the Dufaylite Design Lab.