Not every innovation project leads directly to a new product. Sometimes unexpected insights, technical breakthroughs and new ways of working create the greatest value. This became clear in Fold 2, a SHAPE co-innovation project in which Mirka and other participants explored how folded and structured paper materials could be used in new applications.
For Mirka, the focus was on investigating whether structured paper surfaces could be used in abrasive materials, sanding blocks and packaging solutions. The project started with the question of how smart material structure design could reduce material consumption without compromising functionality.
From origami to industrial applications
The project tested various types of folded paper structures. The idea was to create three-dimensional patterns in the backing of abrasive materials, which could theoretically reduce the need for adhesive and abrasive grains while improving dust extraction.
The work was carried out primarily by developers and laboratory staff at Mirka, who were given considerable freedom to experiment.
“We had a great deal of freedom. This gave us the opportunity to try out many ideas, but also the challenge of finding a direction among all the possibilities,” the project team explains.
The work ranged from developing their own patterns and 3D-printing tools to testing prototypes both in the laboratory and on production equipment.
Promising results for abrasive products
Of the three areas investigated—abrasive materials, sanding blocks and packaging—abrasive materials showed the greatest potential. Tests showed that the structured surfaces performed better than expected in several cases and that the concept may be worth exploring further.
“The fact that we were able to achieve such good sanding performance with the very first prototypes feels very promising,” the team says.
However, the tests showed that the folded structures did not work as well as a replacement for foam in sanding blocks. This, too, is seen as a valuable result.
“A project does not always have to confirm an idea. Learning what does not work is also valuable knowledge.”
New perspectives and new knowledge
The project also yielded several unexpected lessons. One was how strong a folded paper material can become when its geometry is well designed.
“We were surprised by how stable the structures actually were. It is something you do not fully understand until you get to work with the material in practice.”
At the same time, the project provided valuable experience, inspiration and insights from other project participants into the possibilities of advanced folding technology.
More than just technical results
One of the most important insights from Fold 2 was perhaps not about materials or products, but about people. The same people were able to follow the work from start to finish. This fostered stronger engagement, a deeper understanding of the bigger picture and greater opportunities to explore the questions in depth.
“When you get to take part in the entire process, a completely different level of engagement develops. You have time to delve deeper, build on ideas and really get into a flow.”
When the project team sums up Fold 2 in three words, they choose: creative, inspiring and innovative. Although not every idea made it all the way through, the project has shown how collaboration, curiosity and a willingness to experiment can open doors to future innovations.
Fact box: Fold 2
A SHAPE co-innovation project in collaboration between VTT, Aalto University and six industry partners, set out to explore something that has never existed at industrial scale before: a fold‑based manufacturing technology capable of creating high‑performance, sustainable structures from flat sheet materials.
The work builds on the earlier Fold project and carries forward the idea that origami‑inspired geometry can enable an entirely new category of industrial products and processes.
Mirka investigated applications in abrasive materials, sanding blocks and packaging solutions.
The project evaluated how structured surfaces could help reduce material consumption and improve functionality.
The most promising results were achieved in the development of structured abrasive products.