Panel Configuration · Fan-Fold

Fan-Fold

The fan fold is made by alternating scores on opposite face of a panel. The result is an accordion-folded form that ships flat and deploys quickly by a single operator with no tools required. It’s useful for creating quick stack-ups in void fill applications or adding flexibility to a rigid form.

How it works.

The scoring machine applies two blade passes: the first from the top face, the second from the bottom face, with each score positioned at a regular interval. When the scored panel is folded, the alternating hinge points cause the panel to fan out in a zig-zag pattern.

The resulting fan-folded panel behaves like a continuous, self-supporting wall of honeycomb material. It can be bent to follow a curved surface, stood upright to create a vertical barrier, or laid flat to fill the base of a container — all from the same piece.

Technical Specifications

  • Fold Direction

    Alternating — accordion / fan-fold pattern

  • Fold Pitch

    Specified by customer to match application geometry

  • Scores Per Panel

    Multiple — pitch repeated along full panel length

  • Panel Compatibility

    Any flat panel within standard dimension ranges

Design considerations.

  • Fold pitch directly determines deployment behaviour. Shorter pitch = tighter, more compact fan; longer pitch = wider sections with more coverage per fold.

  • Fan-folded panels deploy to a greater height than their folded storage height. Confirm deployed dimensions relative to the container or space being filled.

  • Fan-fold panels can be cut to length at the point of use, giving operators flexibility when filling irregular void spaces.

  • Multiple fan-fold panels can be interlocked or stacked to cover large areas or provide layered protection.

Applications

Common applications.
Representative use cases for fan-fold panels. Every application is custom-engineered — these are illustrative starting points, not standard SKUs.

Dunnage & Void Fill

Deployed inside shipping containers, crates, and cartons to fill void space and prevent product movement during transport.

Automotive Dunnage

Returnable and expendable automotive part packaging to brace stamped panels, castings, and sub-assemblies between product layers.

OTR Shipping

Large-format fan-fold panels for blocking and void fill in over-the-road trailers where coverage area is significant.

Wrapping & Conforming

Fan-folded panels can be bent to conform to curved or irregular product surfaces — providing a honeycomb layer that follows the product profile.

Side Wall Protection

Erected along the interior walls of a shipping container to cushion product from lateral impact during handling and transport.

Layer Separators

Deployed horizontally between stacked product layers to distribute vertical load and prevent crushing of lower-tier items.
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