Different Types of Paper, Card & Lightweight Materials

Design & Technology students often use a range of paper, cardboards, and other lightweight materials used in graphic products and architectural models. This article summarises the properties, stock forms, and common uses of these materials. It concludes with sample examination questions from the Cambridge IGCSE and AS/A Level syllabus.

Students looking at types of paper and cardboard

Common properties of paper, card, and other lightweight materials

  • Readily available
  • Cheap compared to most other materials
  • Accept many different adhesives and finishes (easy to draw, paint, or print on)
  • Easy to cut, score, and fold, requiring less complex machinery and using less energy than plastic moulding or metal fabrication, often with faster assembly (reducing production costs and energy consumption)
  • Can have multiple layers with a cheaper grade in the interior
  • Common forms: A5, A4, A3, A2, A1 etc
  • Good for the environment in general, with some exceptions

Copier paper

Properties

Uses

Lightweight paper used in photocopiers
Inexpensive printed items

Cartridge paper

Properties

Uses

Thicker paper suitable for drawing or paper (comes in various thicknesses / weights)
Can be ‘wetstrength’ (won’t warp when used with wet mediums)
Artwork
Birthday cards

Cardboard

Properties

Uses

Various types, thicknesses and colours
Can be laminated with aluminium or polyethylene layers or other finishes to provide waterproofing
Wide range of lightweight graphic products

Corrugated card

Properties

Uses

Three layers glued together (fluted inner layer sandwiched between two outer layers)
Fluting / corrugation adds strength and rigidity, while remaining lightweight (good strength-to-weight ratio)
Protective packaging
Most common box material

Bleached card

Properties

Uses

Makes a white surface better for drawing / printing on
Sometimes only the top layer bleached
Cereal boxes, food packages

Mount board

Properties

Uses

Good quality thick card
Coloured on one side
Mounting work
Framing work
Premium business cards

Duplex card

Properties

Uses

Two layers of card bonded together (glued or pressed together while wet)
Different colours or textures can be joined
Can emboss one side without indenting the other
Thick, strong, sturdy
More expensive than other card
Premium business cards

Recycled cardboard

Properties

Uses

Made from recycled paper / card
Good for environment (reduces deforestation / uses less raw materials / less waste going to landfill or burned / biodegrades easily)
Marketing opportunity –appeals to environmentally conscious consumers / promotes ‘green’ image
Not suitable for contact with food or other sensitive products like cosmetics, due to contamination issues
Can be weaker, as fibres degrade when recycled (can be mixed with virgin pulp fibres)
Can be discoloured and have other debris so less uniform and ‘imperfect’ in appearance
Corrugated boxes
Cereal boxes (with an inner plastic bag, i.e. a low density polyethylene bag, preventing direct contact with food – and often a bleached outer layer providing better printing properties)

Moulded paper pulp

Properties

Uses

Pulp made from recycled paper & card mixed with water, pressed into moulds and dried
Often thick / rough / textural (however can be pressed smooth)
Packaging
Drink holders
Food trays

Has same pros / cons as recycled card above

Foamboard

Properties

Uses

Has a foam core sandwiched between two layers of card
Lightweight
Good to draw on
Good rigidity
More expensive than cardboard
Not very flexible / bendy
Not good for environment (contains plastic, hard to recycle as a composite material – hard to separate materials for recycling)
Presentations / mounted charts and displays
Models
Retail signage
Point-of-sale displays

Corriflute sheet

Properties

Uses

Like plastic corrugated cardboard
Comes in a range of colours
Lightweight, rigid, great strength-to-weight ratio
Waterproof
Quite expensive
Harder to draw on (could apply stickers to though)
Presentations
Point-of-sale displays
Temporary outdoor signs

Self-adhesive vinyl

Properties

Uses

Thin PVC film with an adhesive layer and peel-off backing paper
Can be printed on with an inkjet printer
Can be cut with a vinyl cutter or plotter cutter (print-and-cut machine)
Range of colours and finishes (glossy, matte, textured)
Waterproof
Comes in big rolls or sheets
Difficult to recycle
Stickers / labels on cups / bottles
Vehicle graphics (bumper stickers etc)
Temporary and permanent signage

NOTE: Static cling vinyl or cling film does not have an adhesive layer, but will naturally stick to glass – used for window stickers etc.

Sticker paper

Properties

Uses

Has an self-adhesive layer and peel-off layer
Comes in standard sheet sizes (i.e. A4) that can go through a printer or plotter cutter
Can have just the top layer cut (called a ‘kiss’ cut) so still attached to the backing paper, so all little pieces are not lost
Not waterproof
Stickers
Labels

You can also buy self-adhesive vinyl sticker paper in A4 sheets etc

Foil-backed card

Properties

Uses

Aluminium layer laminated to one or both sides of the card (composite product)
Waterproof barrier
Also blocks light and oxygen
Difficult to recycle
Food containers (seals in freshness and stops moisture absorbing into card)

PE laminated card

Properties

Uses

Laminated with a layer of polyethylene (composite product)
Waterproof barrier
Glossy protective surface
Difficult to recycle
Food and drink containers (juice cartons, paper cups, fast food packaging)

Tetra Pak®

Properties

Uses

World’s largest manufacturer of shelf-stable drink and liquid food cartons
Composite product with multiple layers including polyethylene (PE) and aluminium foil
Difficult to recycle
Milk and juice cartons

Environmental impact of paper and card

In general, paper and card-based products are very environmentally friendly:

  • Created from sustainable resources (trees)
  • Biodegrade easily (rot away)
  • Can be easily recycled

Challenges of recycling certain graphic products

  • Various finishes or glues can make a product harder to recycle
  • Darker, metallic, or fluorescent inks can be hard to remove during the de-inking process
  • Composite materials (such as foamboard, foil-backed card, or PE laminated card) are much harder and often impossible to recycle, as the different materials require different recycling processes, yet cannot be easily separated
  • Some products (such as pizza boxes) absorb moisture, grease or are contaminated with waste or other chemicals, making them unsuitable for recycling
  • Other additives (such as those used in paper cups to make them resistant to breaking down in moisture) make products hard to recycle
  • Other components, such as staples / bindings can get in the way
  • Paper fibres degrade with each recycling, so can only be recycled a limited number of times

When recycled, paper is pulped (mixed with water), de-inked, filtered for contaminants, and cleaned of unwanted chemicals. Anything that doesn’t break down in water or can’t be filtered out causes problems.

You may also wish to learn about different printing and surface treatments for paper-based products!