Dufaylite Design Lab: Episode 3

Ultra Board sofa build: Recyclable Seating for Exhibitions and Events

The Ultra Board sofa build proves how recyclable display materials can be transformed into branded, full-size seating for exhibitions, events and pop-ups. Designed entirely from FSC® certified paper honeycomb board, it shows printers how to create practical furniture using sustainable materials without glue, tools or waste.

This sofa build highlights how recyclable seating can meet real-world performance demands, delivering comfort, brand impact and structural strength. For printers working in temporary display environments, it offers a fast-build, lightweight, plastic-free alternative to foam-based or PVC furniture – ideal for those offering sustainable event furniture.

Watch the Ultra Board sofa build

Want to feel the strength behind recyclable seating?

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

Get hands-on with the same FSC® certified paper honeycomb board used in the Ultra Board sofa build by requesting a free bee-shaped sample. It’s lightweight, printable, fully recyclable and built to handle real load – ideal for exploring structural display materials before your next exhibition, pop-up or event seating project.

Don’t just take a seat – request your sample today.

How to build recyclable seating for printers

It started with a challenge: could sustainable display materials be used to build a sofa that looks the part, works under load, and prints like a dream? Using CAD-led design, precision cutting and smart folding techniques, the Dufaylite Design Lab team created a modular, branded seating unit that slots together in minutes. With no adhesives or screws, and fully flat-packable, the Ultra Board sofa build demonstrates how recyclable seating for printers can be ready for high-traffic events and sustainably produced in-house by printers. This makes it suitable not only for exhibitions and pop-ups, but also for festivals, communal spaces and temporary accommodation environments.

The Process

How the sofa was built using recyclable display board

CAD-cut slot-fit design for fast, accurate, tool-free assembly
V-groove folds to increase strength and define clean lines
Internal support panels distribute load and increase durability
Smooth liner surface for direct printing or custom wrapping
Built entirely from high-strength paper honeycomb board
Flat-pack format for efficient transport, handling and storage

The Result

Recyclable seating printers can build and brand

The Ultra Board sofa build delivers on printability, strength and sustainability, helping printers create modular event seating that aligns with eco goals.

Supports 2–3 adults with load-bearing strength
Lightweight and easy to transport
Designed for rapid assembly and disassembly
Printable and brandable for client campaigns
Made from recyclable display board and fully plastic-free
Ideal for retail environments, exhibitions, or corporate activations
Lightweight yet strong, offering similar performance benefits to the Ultra Board chair build

A modular, branded seating solution designed for print, engineered for events.

Key benefit for printers creating recyclable seating

Fast to cut, assemble and brand using standard printer workflows
Strong enough for real event use – light enough to handle easily
Printable surface for direct graphics or vinyl-wrapped branding
100% recyclable, made from FSC® certified paper honeycomb board
Designed for reuse, modular layouts and multi-site campaigns
Helps printers reduce plastic use while offering sustainable event furniture

Selecting the right Ultra Board for recyclable seating and furniture

For printers creating branded seating, exhibition furniture or structural POS, the Ultra Board range offers purpose-built grades to match strength, surface and sustainability needs.

3D and 3D White

Universal

Graphic

2D and 2D White

3D and 3D White

The strongest options for building sofas, chairs and structural display furniture.

Universal

Natural brown board ideal for wrapped graphics or rustic, eco-led finishes.

Graphic

Lightweight and cost-effective for signage, backdrops or budget-friendly builds.

2D and 2D White

Slimline boards for everyday eco signage and print mounting.

Each board is made from recyclable paper honeycomb and engineered for clean cutting, easy assembly and professional print results.

Compare Ultra Board Grades

Request a Free Sample ›

Frequently Asked Questions

Can recyclable materials really be used to create event seating?

Yes. Recyclable materials like paper honeycomb board have been successfully used to build full-size, load-bearing seating for real events. The Ultra Board sofa build is proof that sustainable event furniture can combine comfort, strength and brand impact. Designed for printers, it provides a fully recyclable, tool-free solution that assembles quickly and supports multiple adults. It’s ideal for exhibitions, trade shows, product launches or retail pop-ups where branded seating needs to be both practical and planet-friendly.

What is the best sustainable material for recyclable seating?

Paper honeycomb board is one of the best sustainable materials for creating recyclable seating for printers. Lightweight yet strong, it’s made from recycled paper and fully recyclable after use. The Ultra Board sofa build is a great example – it can be wrapped in custom graphics, cut to size using CAD, and flat-packed for easy transport. Printers use this material to supply seating for temporary lounges, brand activations and showroom installations that need to impress without leaving plastic waste behind.

Can the Ultra Board Sofa be printed or customised for client campaigns?

Yes. Ultra Board features a smooth liner surface that allows for direct-to-board printing or full graphic wraps. This enables printers to fully customise the sofa with campaign branding, colour-matched visuals, or client messaging. Whether it’s a seating zone at a conference, a themed activation at a festival, or a branded space inside a retail popup, this sofa can be tailored to match the environment while reinforcing the client’s sustainability credentials.

How is the sofa assembled for events or exhibitions?

The Ultra Board sofa build is designed with simplicity in mind. All parts are CAD-cut from recyclable board and use a slot-together system with V-groove folds. No tools, glue or screws are needed. This allows printers or event contractors to build the structure on-site in minutes. Perfect for setups with tight timeframes or frequent changeovers, such as touring exhibitions, pop-up installations, or brand showcase booths.

Is the sofa strong enough for high-traffic events or temporary seating zones?

Yes. The Ultra Board sofa build has been structurally tested to support two to three adults. Thanks to its internal support panels and engineered honeycomb core, it offers surprising strength despite its lightweight design. This makes it a reliable seating solution for busy exhibitions, networking areas or client lounges, where comfort, style and sustainability all need to show up in one build.

Explore more recyclable display furniture in the Dufaylite Design Lab

The Ultra Board sofa build is just one of many innovative projects developed in the Dufaylite Design Lab. Each build demonstrates how paper honeycomb board can be transformed into fully functional, brandable and recyclable display solutions, designed specifically for printers working across events, retail, exhibitions and POS. From seating and storage to banners and structural signage, these videos showcase how printers can push recyclable display materials further and turn flat board into bold, sustainable builds.

See what’s possible with recyclable display furniture