Double-Sided Micro-Corrugated Board (E-Flute)

The Professional Standard for Low Profile Structural Modelling and Intricate Prototyping

This high specification micro corrugated board (E flute), which is also often referred to as micro flute, is engineered for applications where low material thickness must be combined with high dimensional stability. Clad on both sides with high quality liners, the board offers a smooth, uniform surface that conceals its internal corrugated structure. This makes it an ideal choice for professionals requiring a lightweight yet rigid substrate that maintains its form under compression. It is an excellent material for scale models due to its lightweight structural strength and authentic textures, making it widely used in architectural, railway, and diorama modelling to effectively simulate industrial roofing, metal cladding, and structural foundations.

Key Performance Features

• Optimised Dimensional Stability: The 1.5mm E flute core provides significant rigidity, making it suitable for larger scale architectural models where standard card might sag.
• Double Sided Premium Finish: Clad on both sides with high quality liners to ensure a professional finish on both interior and exterior surfaces, allowing for precise drawing, digital printing, or the clean application of additional veneers.
• High Strength to Weight Ratio: Offers a dense, smooth finish that easily supports its own weight and resists minor crushing while remaining easy to handle and move.
• Climate Sensitivity Note: As a paper based product, it may react to changes in humidity. For precision applications, ensure the material is stored flat in a dry environment.

Essential Tools for Precision Work

Having the right tools ensures crisp, clean edges and prevents the board from crushing or tearing during fabrication.

• Cutting Mat: A self healing rotary cutting mat provides a stable, grid lined surface for layout work.
• Blades: A craft knife with sharp number 11 blades is essential. It is highly recommended to change blades frequently, as dull blades drag and tear the paper layers.
• Ruler: A steel metal ruler should always be used for guiding straight edges and ensuring safe, controlled cuts.
• Adhesives: Compatible with standard PVA or specialised UHU hard glue. Using a squeezable precision bottle allows you to apply your chosen adhesive with pinpoint accuracy.

Working and Shaping Techniques

• Scoring for Clean Folding: To create a perfect 90 degree bend, use your knife to carefully cut only the top layer of paper and the flute directly underneath it. Leave the bottom liner layer completely intact, which acts as a hinge and allows you to fold the board smoothly.
• Layering for Terrain Contours: Because micro corrugated board features a uniform thickness and is easily stackable, you can trace topographic map contour lines onto multiple sheets, cut them out, and stack them on top of one another to build highly realistic 3D terrain models.
• The Water and Peel Method: To expose the internal textured structure, you can submerge a piece of standard double sided corrugated board in a bowl of water. Once the paper is saturated, you can easily peel off one of the flat exterior liners, leaving you with a perfect, exposed micro corrugated texture for industrial roofing or cladding aesthetics.
• Embossing Custom Textures: For ultra thin details, you can roll thin metal sheets, such as fine aluminium sheet, over a corrugated template or a commercial embossing machine to create highly realistic corrugated iron effects guided by this board.

Technical Specifications

• Flute Type: E Flute (Micro corrugated)
• Thickness: 1.5mm
• Dimensions: 1000 x 700 mm
• Quantity: See options
• Weight (White Kraftliner): 125 g/m per side
• Weight (Brown Kraftliner / Testliner): 125 g/m / 140 g/m

Applications

• Architectural Model Making: An essential material for constructing structural massing, detailed 1:50 or 1:100 facades, interior partitions, and stable base plates.
• Prototyping and Industrial Design: Ideal for creating high fidelity packaging prototypes, consumer product mock ups, and functional volumetric studies.
• Film and TV Scenic Design: A versatile material for constructing lightweight set panels, decorative cladding, and rigid props that accept scenic paints and adhesives without warping.
• Graphic Design and Display: Frequently used for rigid presentation boards, point of sale mock ups, and protective exhibition layers where high resolution labelling or mounting is required.

Comparison between Micro, Single, and Double Corrugated Board

Corrugated boards are classified by their layer thickness and flute sizes. Choosing the correct board depends on the balance required between intricate detail and structural strength for your project.

• Micro Corrugated Board: Ultra thin boards usually between 1.0mm and 2.0mm thick. This is the ultimate choice for visible, aesthetic models, intricate architectural details, consumer product packaging mock ups, precise laser cutting, and projects requiring fine, curved details.
• Single Corrugated Board: The industry standard single wall option. It is best for rapid architectural prototypes, large scale structural models, and heavy, unpainted model bases.
• Double Corrugated Board: Composed of a heavy duty, double wall fluted layer. This is best for large, weight bearing models, heavy topographical landscapes, or foundational blocks where maximum rigidity and puncture resistance are prioritised.