Corrugated cardboard

Physical properties

Laser processing

Fumes are purely cellulosic plant-based (smell of burnt paper), non-toxic. Standard extraction is required to keep the optics clean and evacuate the smell.

CO₂: CO2 laser cutting is exceptional and very fast. It requires very low power (10–20W) at high feed rates. The intermediate corrugated edges show slight natural carbonisation that does not affect the structure.

Diode: Excellent behaviour. Even low-power diode lasers (5W+) cut it quickly at high speed. Be careful not to generate embers.

Fiber: Not applicable.

CNC / milling processing

Not workable with CNC and traditional rotating milling bits: the tool's stress would crush the internal wave structure and tear the outer paper faces.

Plotter and thermoforming

Excellent for thin single-wave thicknesses (≤2mm). Requires deep blades for thick materials and careful pressure calibration to cut without crushing or compressing the internal wave structure.

Post-processing

Sanding: Not sandable.

Gluing: Excellent structural bonding, very fast with hot glue, PVA glue, or double-sided tape. The porosity of the paper ensures minimal curing times.

Over time: Highly biodegradable. Sensitive to water and humidity (wetting instantly destroys the cardboard's structural rigidity). Yellows if exposed to direct light.

Common defects

• Flute crushing or collapse of the internal wave structure if processed mechanically with pressure or unsuitable tools
• Flame ignition in the honeycomb layer during laser cutting if speed is too slow or air assist is absent

Safety

Corrugated cardboard is highly flammable. Never leave the laser unattended and ensure pneumatic assistance (air assist) is active to extinguish sparks.

Availability and formats

Commercial formats: single-wall panels 2–3mm, double-wall panels 5mm, die-cut boxes

Related materials

Sources

• ISO 5636 — Paper and board quantitative permeability specifications
• Manuali operativi FabLab di prototipazione rapida strutturale