Utilizing Corrugate Nesting Structures to Replace Polystyrene, Polyurethane, and Wood Nesting Solutions

Corrugated plastic and fiberboard can deliver the cushioning, stability, and stackability you need—without the cost, weight, or disposal challenges of polystyrene, polyurethane foams, and wood. This resource shows how to design corrugate nesting structures that protect parts in transit and storage, while improving sustainability, reducing waste, and lowering total cost of ownership.

What you’ll learn in this resource:

• Performance advantages of corrugate nests (lightweight, impact dispersion, moisture resistance)
• Design approaches for part-specific nests (die-cuts, cells, ribs, and honeycomb cores)
• How corrugate compares to EPS/PU foams and wood on cost, recyclability, and ergonomics
• Implementation steps: material selection, prototyping, testing, and supplier collaboration
• End-of-life pathways (reuse cycles, repair, and high-recovery recycling options)

Download the guide now to replace heavy and hard-to-recycle nesting with efficient, recyclable corrugate solutions.

FAQs

Why switch to corrugate from foam or wood?
Corrugate is lighter, typically lower cost, and easier to recycle at scale. It reduces ergonomic strain, freight costs, and landfill fees associated with foam and wood.

Will corrugate protect parts as well as foam or wood?
Yes—when engineered with the right profiles (e.g., flutes, multi-layer laminations, honeycomb board) corrugate can match or exceed cushioning and load distribution for many applications.

What design features should I consider?
Use die-cut cradles for precision fit, multi-layer laminations for stiffness, ribbed inserts for shear control, and cellular/honeycomb cores for high compression strength with minimal weight.