cardboard

78 Articles

Luthier Crafts Guitar From Cardboard

March 27, 2026 by 17 Comments

The people at Signal Snowboards are well known not only for producing quality snowboards, but doing one-off builds out of unusual and perhaps questionable materials just to see what’s possible. From pennies to glass, if it can go on their press (and sometimes even if it can’t) they’ll build a snowboard out of it. At some point, they were challenged to build different types of boards from paper products which resulted in a few interesting final products, but this pushed them to see what else they could build from paper and are now here with an acoustic guitar fashioned almost entirely from cardboard.

For this build, the luthiers are modeling the cardboard guitar on a 50s-era archtop jazz guitar called a Benedetto. The parts can’t all just be CNC machined out of stacks of glued-up cardboard, though. Not only because of the forces involved in their construction, but because the parts are crucial to a guitar’s sound. The top and back are pressed using custom molds to get exactly the right shape needed for a working soundboard, and the sides have another set of molds. The neck, which has the added duty of supporting the tension of the strings, gets special attention here as well. Each piece is filled with resin before being pressed in a manner surprisingly similar to producing snowboards. From there, the parts go to the luthier in Detroit.

At this point all of the parts are treated similarly to how a wood guitar might be built. The parts are trimmed down on a table saw, glued together, and then finished with a router before getting some other finishing treatments. From there the bridge, tuning pegs, pickups, and strings are added before finally getting finished up. The result is impressive, and without looking closely or being told it’s made from cardboard, it’s not obvious that it was the featured material here.

Some of the snowboards that Signal produced during their Every Third Thursday series had similar results as well, and we actually featured a few of their more tech-oriented builds around a decade ago like their LED snowboard and another one which changes music based on how the snowboard is being ridden.

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The Cardboard Airplane Saga Continues

November 9, 2025 by 25 Comments

History is full of engineers making (or attempting to make) things out of the wrong stuff, from massive wooden aircraft to boats made of ice and sawdust. [PeterSripol] is attempting to make an ultralight aircraft out of a rather wrong material: cardboard. In the previous installment of the project, a pair of wings was fabricated. In this installment, the wings find their home on an equally mostly cardboard fuselage, complete with rudder and elevator. 

The fuselage construction amounts to little more than a cardboard box in the shape of an RC airplane. Doublers provide additional strength in critical areas, and fillets provide a modicum of additional strength around seams. To support the weight of the pilot, a piece of corrugated cardboard is corrugated again, with an additional piece making up the floor. With the addition of a couple of side windows for comfort and visibility, the fuselage is completed, but additional components need to be added.

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Making A Cardboard Airplane Wing

October 24, 2025 by 21 Comments

Ideally, an aircraft would be made of something reasonably strong, light, and weather resistant. Cardboard, is none of those things. But that did not stop [PeterSripol] from building an ultralight wing out of cardboard.

Firstly, he wanted to figure out the strongest orientation of the cardboard flutes for the wing spars. He decided on a mix of horizontal and vertical flutes for the wing spar, with the horizontal flutes resisting vertical deformations and the vertical flutes resisting chord wise deformations.

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Making Corrugated Cardboard Stronger And Waterproof

June 15, 2025 by 47 Comments

As useful as corrugated cardboard is, we generally don’t consider it to be a very sturdy material. The moment it’s exposed to moisture, it begins to fall apart, and it’s easily damaged even when kept dry. That said, there are ways to make corrugated cardboard a lot more durable, as demonstrated by the [NightHawkInLight]. Gluing multiple panels together so that the corrugation alternates by 90 degrees every other panel makes them more sturdy, with wheat paste (1:5 mixture of flour and water) recommended as adhesive.

Other tricks are folding over edges help to protect against damage, and integrating wood supports. Normal woodworking tools like saws can cut these glued-together panels. Adding the wheat paste to external surfaces can also protect against damage. By applying kindergarten papier-mâché skills, a custom outside layer can be made that can be sanded and painted for making furniture, etc.

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A painted RC plane made of cardboard. It has an orange propeller and camo-esque markings along with concentric blue, white, and red circles near the wingtips.

Cardboard R/C Plane Actually Flies

August 1, 2024 by 19 Comments

Many makers start by building mock-ups from cardboard, but [Alex-08] has managed to build an R/C plane that actually flies, out of cardboard.

If you’ve been thinking of building an R/C plane from scratch yourself, this guide is an excellent place to start. [Alex-08] goes through excruciating detail on how he designed and constructed this marvel. The section on building the wings is particularly detailed since that’s the most crucial element in making sure this plane can get airborne.

Some off-the-shelf R/C parts and 3D printed components round out the parts list to complement the large cardboard box used for most of the structural components. The build instructions even go through some tips on getting that vintage aircraft feel and how to adjust everything for a smooth flight.

Need a wind tunnel instead? You can build that out of cardboard too. If paper airplanes are more your thing, how about launching them from space? And if you’re just trying to get a head start on Halloween, why not laser cut an airplane costume from cardboard?

Swapping Vinyl For Cardboard With This ESP32 Turntable

June 30, 2024 by 15 Comments

Cardboard is a surprisingly durable material, especially in its corrugated form. It’s extremely lightweight for its strength, is easy to work, can be folded and formed into almost any shape, is incredibly inexpensive, and when it has done its duty it can be recycled back into more paper. For these reasons, it’s often used in packaging material but it can be used to build all kinds of things outside of ensuring that products arrive at their locations safely. This working cardboard record player is one example.

While the turntable doesn’t have working records in the sense that the music is etched into them like vinyl, each has its own RFID chip embedded that allows the ESP32 in the turntable’s body to identify them. Each record corresponds to a song stored on an SD card that instructs the ESP32 to play the appropriate song. It also takes care of spinning the record itself with a small stepper motor. There are a few other details on this build that tie it together too, including a movable needle arm held on with a magnet and a volume slider.

As far as a building material goes, cardboard is fairly underrated in our opinion. Besides small projects like this turntable, we’ve also seen it work as the foundation for a computer, and it even has the strength and durability to be built into a wall or even used as shelving material. And, of course, it’s a great material to use when prototyping new designs.

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The end result of the build, a supersized ultrasonic sensor, held in a person's hands

A Super-Size Functional Tribute To An Ultrasonic Sensor

June 1, 2024 by 6 Comments

Sometimes, it’s time to shut down the oscilloscope, and break out the cardboard and paints. If you’re wondering what for, well, here’s a reminder of an Instructable from [CrazyScience], that brings us back to cardboard crafts days. They rebuild one of the most iconic components for an electronics tinkering beginner — an ultrasonic distance sensor, and what’s fun is, it stays fully functional after the rebuild!

This project is as straightforward as it gets, describing all the steps in great detail, and you can complete it with just a hot glue gun and soldering iron. With materials being simple cardboard, aluminum foil, popsicle sticks, some mesh, and a single ultrasonic sensor for harvesting the transmitter and receiver out of, this is the kind of project you could easily complete with your kids on a rainy day.

Now, the venerable ultrasonic sensor joins the gallery of classics given a size change treatment, like the 555 timer we’ve seen two different takes on, or perhaps that one Arduino Uno. Unlike these three, this project’s cardboard skeleton means it’s all that simpler to build your own, what’s with all the shipping boxes we accumulate.

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