Mortise and Tenon Structure in Packaging: Corrugated Paper’s Glue-Free Magic for Stable, Sustainable ContainersBy：BellaBella

Corrugated Paper Mortise-and-Tenon Packaging: More Than “Nostalgia,” It’s a New Eco-Solution 

Traditional corrugated packaging relies on glue or tape for stability. This not only complicates recycling (glue residues contaminate paper fibers) but also risks breakage during shipping if adhesion is weak. The core of the mortise-and-tenon structure lies in the precise fit between “protruding tenons” and “recessed mortises,” allowing the corrugated paper to support itself: 

Cutting Logic: Based on the packaging’s size and load-bearing needs, trapezoidal, rectangular, or dovetail-shaped tenons and mortises are pre-cut into the corrugated paper, with a margin of error controlled within 0.1mm to ensure a tight fit during assembly. 

Assembly Principle: No tools are required—simply align the tenon with the mortise and push gently. The toughness of the corrugated paper fibers locks the joint in place, creating a “self-locking” effect. Its load-bearing capacity is 1.2 times that of traditional glued packaging. 

Eco-Advantages: No glue, nails, or extra materials are used. When discarded, the packaging can be easily disassembled into single-material corrugated paper, boosting recycling rates to 98%—far higher than the 75% of standard glued packaging. 

Three Core Mortise-and-Tenon Structures: Corrugated Packaging for Every Need  

We’ve designed three mainstream mortise-and-tenon structures to meet the packaging requirements of food, beauty, electronics, and other industries—balancing stability and practicality: 

Dovetail Joint: The “Safety Lock” for Heavy-Load Scenarios 

Structure Features: Tenons are trapezoidal (dovetail-shaped), with matching mortises. Once assembled, the shape prevents lateral detachment, offering exceptional resistance to stretching and compression. 

Ideal Uses: Packaging for electronic devices (e.g., headphones, small appliances) and glass-bottled products (e.g., sauces, wine). It can bear 5–8kg and reduces shipping breakage rates by 90%. 

Design Detail: A 0.5mm “buffer gap” is left at the joint. This avoids paper cracking from over-tight assembly while leveraging the corrugated paper’s elasticity to enhance stability. 

Right-Angle Joint: The “Convenient Option” for Easy Assembly 

Structure Features: Both tenons and mortises are rectangular. Cutting is simple, and assembly takes just 30 seconds—even for first-time users. Perfect for scenarios where consumers need to assemble the packaging themselves. 

Ideal Uses: Shipping cartons and foldable gift boxes (e.g., holiday gift sets, beauty sample kits). They can be folded flat for transport, saving 60% of storage space. 

Slot Joint: The “Organizer” for Flexible Partitioning 

Structure Features: Vertical or horizontal slots are cut into the main corrugated paper body, paired with separate “divider panels.” The panels fit into the slots to create multi-compartment storage, with adjustable space between partitions. 

Ideal Uses: Multi-piece lip balm sets, scented candle kits, and snack gift packs. It prevents products from colliding and scratching inside the box while improving the packaging’s neatness. 

Innovation: The slot edges are rounded to prevent hand scratches during assembly and reduce wear on the corrugated paper’s corners, extending the packaging’s lifespan. 

From Design to Implementation: Making Mortise-and-Tenon Packaging Your Brand’s “Eco-Card” 

Last year, we created a custom mortise-and-tenon corrugated package for an organic snack brand. Not only did this reduce the brand’s packaging costs by 30% (eliminating glue and tape expenses), but its “disassemblable, reusable” nature also sparked spontaneous consumer sharing—many users repurposed the empty boxes into storage organizers or bookshelf dividers, acting as “free brand advocates.” 

For eco-friendly packaging, “stability” and “sustainability” are never mutually exclusive. The mortise-and-tenon corrugated structure solves modern packaging pain points with traditional craftsmanship, turning every package into a carrier for a brand’s eco-values. Moving forward, we’ll continue to refine mortise-and-tenon designs and explore thinner, higher-load corrugated materials—making “glue-free stability” a viable packaging solution for more industries.