Work

Investigating the Three‐Dimensional Forming of Microfibrillated Cellulose‐Coated Paperboard With Full and Localised Coatings in Thermoforming, Hydroforming and Deep Drawing

Year: 2025

Type: article

Abstract: ABSTRACT The shift towards sustainable packaging has increased interest in fibre‐based materials, such as paperboard, as alternatives to plastics. However, the limited formability of paperboard presents challenges in producing intricate three‐dimensional (3D) geometries. This study examined the 3D forming capabilities of microfibrillated cellulose (MFC)‐coated paperboards in comparison with uncoated and polyethylene terephthalate (PET)‐coated paperboards using three forming processes: thermoforming, hydroforming and deep drawing. The influence of applying MFC as either full or localised coatings on formability and directional strain behaviour is systematically evaluated. Material strain behaviour is assessed using bulge testing and quantitative profile measurements during the forming process. The findings demonstrate that the studied MFC coatings enhance material formability, with full coatings of fluidised MFC providing the most consistent performance improvements across fixed‐blank forming methods and different geometries. Under fixed‐blank forming conditions, the formability of MFC‐coated paperboard is comparable to that of PET‐coated samples. Furthermore, the results indicate that localised coatings affect the overall deformation behaviour of the entire blank rather than producing purely local effects. However, placing the coating edges within the active‐forming zones increases the risk of delamination. Thermoforming produces greater gains in formed area than hydroforming because of the combined effects of heat and pressure. Hydroforming is more sensitive to coating patterns than thermoforming, particularly in partially coated configurations. Conversely, deep drawing, which relies on a distinct forming process, exhibits the smallest yet still favourable impact of the coating, as evidenced by improved wrinkle formation.

Source: Packaging Technology and Science

DOI: 10.1002/pts.70039

Authors: Sanaz Afshariantorghabeh, Cédric Brunk, Peter Groche, Ville Leminen

Institutions: Lappeenranta-Lahti University of Technology, Technische Universität Darmstadt

Language: English

Topic: Material Properties and Processing

Subfield: Mechanics of Materials

Field: Engineering

Domain: Physical Sciences

Open Access status: hybrid

Estimated APC paid: $4,150

Funder: Deutsche Forschungsgemeinschaft