Manufacturing and characterization of innovative lightweight wooden furniture from polystyrene core wood sandwich panels

Abstract

The increasing demand for lightweight and sustainable furniture has highlighted the need for innovative materials with improved performance characteristics. In this study, a light wood sandwich panel (HM) was produced by incorporating polystyrene cores, and lightweight furniture was manufactured using these panels. The primary objective was to develop alternative lightweight materials for furniture production and to perform a comparative analysis of the physical and mechanical properties of HM, medium density fiberboard (MDF), and particleboard (PB). Physical and mechanical characterization tests, including swelling, water absorption, internal bonding strength, screw withdrawal force, and modulus of rupture, were conducted on HM boards and compared with MDF and PB. Results showed that HM boards were 77% lighter than MDF and 16% lighter than PB. HM exhibited the lowest swelling and water absorption values and the highest internal bonding strength among the tested materials. However, the screw withdrawal force and modulus of rupture of HM were lower than those of MDF and PB. Despite these limitations, HM panels demonstrated superior lightweight characteristics and high water resistance. Further improvements in mechanical properties are possible through the use of stronger adhesives and fastening techniques. Overall, the findings indicate that HM panels offer a promising alternative for lightweight furniture production, potentially reducing wood consumption and production costs, while creating more ergonomic products. © 2025 Elsevier B.V., All rights reserved.