Why Honeycomb Board Is Rebul’s Most Versatile Packaging Material

The smarter, stronger, lighter way to protect what matters.

For decades, packaging has been a balance between protection and practicality. Businesses needed solutions that were strong enough to safeguard their products, yet light enough to move efficiently.

At Rebul, we’ve spent over 20 years perfecting that balance – combining engineering precision with sustainable design. Our honeycomb board, represents the next generation of packaging performance: strong, lightweight, recyclable and proudly Australian-made.

Used across crates, pallets, internal supports and so much more, honeycomb board has quickly become a go-to material for businesses that want to protect their products while reducing freight costs and environmental impact.

And while Rebul continues to design and manufacture timber crates for projects that demand maximum rigidity and multi-use performance, honeycomb offers a smarter solution for projects where weight, efficiency, and sustainability take priority.

Rebul Honeycomb Crate

Rebul Honeycomb Internal Packaging Support

What Is Honeycomb Board and Why It Works

Inspired by nature, perfected by engineers.

Rebul’s honeycomb board features a hexagonal paper core structure, similar to a beehive – designed to distribute weight evenly across the surface. This simple yet ingenious design gives the board exceptional compression strength without unnecessary bulk.

The result? Packaging that’s incredibly strong, impact-resistant and easy to handle, yet a fraction of the weight of wood or foam.

Because every sheet is manufactured in Australia from FSC-certified paper, Rebul’s honeycomb materials are as sustainable as they are practical. They’re recyclable, renewable and engineered to meet the toughest transport and export conditions.

Engineered for Real-World Performance

At Rebul, packaging is a science. Each crate, panel and sheet is tested for compression, vibration, and impact resistance, ensuring your goods stay protected from loading bay to destination.

It’s the same engineering philosophy that made our Rebul Crate an award-winner, trusted by galleries, furniture makers, manufacturers and logistics companies worldwide.

Honeycomb board adds a new dimension to that legacy. It combines strength with simplicity, providing consistent performance across industries, while reducing handling time, shipping weight and compliance barriers.

Inside the Rebul Honeycomb Range

Rebul’s honeycomb products are designed to solve real packaging challenges – whether you’re exporting art, stabilising furniture, or moving industrial equipment. Every product can be customised to your exact size, weight and strength requirements.

Honeycomb Crates

The hallmark of Rebul innovation. Honeycomb crates deliver reliable strength and shock absorption, protecting valuable or fragile goods during transit. They’re lightweight, flat-packable and reusable, with no nails, splinters, or fumigation required.

Ideal for industries that need dependable protection without the weight of timber.

Honeycomb Sheets

These engineered panels are the foundation of our system – available in multiple thicknesses, densities and custom-cut options. They’re perfect for void filling, reinforcement, or substrate applications, and can be CNC-shaped for precision.

Honeycomb Pallets

Strong, sustainable, and surprisingly light. Rebul’s paper honeycomb pallets can support more than a tonne while weighing only 3–6 kg. Fully ISPM-15 compliant, they’re export-ready without fumigation or stamping delays.

Internal Supports & Void Fillers

Custom inserts, corner protectors and interlayers made from honeycomb board keep goods stable and shock-free during transit – a cleaner, recyclable alternative to foam or plastic fillers.

Why Businesses Choose Honeycomb

It’s not about replacing wood or foam – it’s about providing more options for better results.

Rebul’s honeycomb solutions help businesses:

Reduce Freight Costs – Lighter shipments mean lower transport expenses and improved handling efficiency.
Increase Sustainability – 100% recyclable, FSC-certified materials reduce landfill and support greener operations.
Improve Protection – Shock-absorbing structure minimises damage from vibration and impact.
Simplify Compliance – Fully ISPM-15 exempt, eliminating fumigation and export delays.
Enhance Storage & Reuse – Flat-packable and easy to reassemble when needed.

It’s the smart packaging solution that balances performance, efficiency and environmental responsibility, backed by Rebul’s decades of experience in manufacturing both timber and composite designs.

See how Rebul’s honeycomb board supports industries from art and furniture to manufacturing and logistics.

Sustainability That Goes Beyond Materials

Sustainability isn’t just a claim at Rebul – it’s part of every design decision.

Our honeycomb board is made using FSC-certified recycled paper, eco-friendly adhesives and a low-waste manufacturing process. Every offcut is recycled and every product is designed for minimal environmental impact.

Because honeycomb is so lightweight, it naturally reduces freight emissions – allowing businesses to ship more products per load while using less fuel. And when a crate reaches the end of its life, it can be recycled back into the system, closing the loop.

That’s the Rebul difference: innovation that makes sense for your products, your customers and the planet.

Stronger. Lighter. Smarter.

Rebul’s honeycomb board isn’t just a new material, it’s the evolution of smart packaging.

It brings together everything we value: strength, precision, sustainability and design flexibility. It’s built for businesses that want packaging to work harder – to protect better, weigh less and perform more efficiently.

And for projects that require something even tougher, our timber and hybrid systems remain an integral part of the Rebul range. Because every product deserves the right protection and every client deserves a packaging partner who can engineer it.

Experience the Rebul difference.
Talk to our team today about creating a smarter, more sustainable packaging solution for your business.

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FAQs: Honeycomb Board, Explained