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Which materials can I replace with PaperShell?

PaperShell can replace wood, plastics, fiber composites and in some cases metal sheets in a number of applications in different markets. The highest environmental and cost effect is to replace aluminium and fiber composites like glasfiber.

For which products can the material be used?

The range of products that the material can be used for is wide as pressing can be done in a wide thickness and 3D-geometry span. Parts can thus be both aesthetic and/or load bearing.

What does the material consist of?

It consists of the same building blocks as wood or plants: Cellulose, hemicellulose (derivative), and in some cases lignin. The source is from the forest, and we collaborate with local or Swedish producers who restore cultivated forests to deciduous or natural forests. Currently, hemicellulose comes from by-products from agriculture without competing with food production.

What can be produced? What are the limitations? Size, thickness, shape.

PaperShell is mainly based on compression molding meaning that you can achieve basically the same geometries as pressed sheet metal but also complex geometries achieved with fiber composites and certain injection molding geometries.

What are the capabilities of this material in terms of design and shape?

It can achieve many of the same designs and shapes that plastics and press moulded metal sheets can.

What does the material weight?

The material has a density of 1,34 gr/cm3 but is stronger than wood and plastics having a good strength-to-weight ratio meaning less need for material. A rule of thumb is 2 mm thick component in PaperShell has the same weight and strength as a component of 1 mm aluminium but the PaperShell component will have >90% less impact and will be >10% cheaper with similar tooling cost.

How thick/think can the material get?

Our normal span is 1,5 to 5 mm thick but we can produce parts that are 0,5 mm and all the way up to 20 mm.

What colours can you get the material in? Can it be surface-treated?

The natural colour of PaperShell is light brown to almost black with a carbon colour look. It is of course possible to paint or foil PaperShell in any preferred colour but then you lose the highly valued PaperShell appearance. It’s also possible to dye the paper before pressing in darker shades of blue, red & green.

Can the material be used externally?

Yes – we have conducted extensive testing to evaluate performance in an outdoor environment. There is a natural wood-like ageing of the surface of the material while the mechanical performance is kept at its high original level.

How does the appearance of the material change over time?

Indoor it stays the same. Outdoor, without any surface treatment, it turns silver grey like wood in 3-6 months, but without the performance loss found in wood.

How is the material heat resistant?

PaperShell has high Glass Transition Temperature (Tg) is approximately 145°C and thus long-term use at elevated temperatures is possible. We also have versions of the materials that have fire and high heat resistance.

In what way is the material circular?

In several ways. Input materials are 100% bio based. All or most parts are waste streams. It is long lasting, traceable and material efficient. It stores atmospheric (biogenic) carbon. Production waste is fed back into the loop. End-of-Life it can be recycled as wood or bio upcycled. Ask us because here we are really nerdy and love to help you transition towards a circular bio economy.

In what way is the material sustainable?

It’s totally biobased and contains 0,00% fossil based carbon. The production process is highly energy and resource efficient and automated. End of life it can be returned to nature and bio upcycled.

What happens to the material at end-of-life?

At recycling stations globally it is sorted as wood and goes into this fraction for recycling or incineration. If incinerated it realises the atmospheric carbon. However, we have collaborations in place to support creating closed loops enabling PaperShell to be returned back to nature and creating carbon neutral and regenerative circular bio solutions.

Is the material traceable?

Yes, both upstream and if you want downstream as well and we have the possibility to trace each component helping you to have circular business models such as PaaS, Take-back and the like.

Where does the manufacturing take place?

Yes, both upstream and if you want downstream as well and we have the possibility to trace each component helping you to have circular business models such as PaaS, Take-back and the like.

What is PaperShell’s customer journey?

We need a CAD or picture of the product/ product in mind and the number of units needed. Based on your goals and requirements we send you a quote. For more info visit our page Customer Journey.

How large volumes can you produce?

We need a CAD or picture of the product/ product in mind and the number of units needed. Based on your goals and requirements we send you a quote. For more info visit our page Customer Journey.

Pricing

It of course depends on the component and the volume. A rule of thumb is a 2 mm thick component in PaperShell has the same weight and strength as a press molded component of 1 mm aluminium. In comparison, a PaperShell component will have >90% less environmental impact, >10% lower in price and a tooling price that is 30-50% lower than an injection molding tool.

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