Wood material and method of manufacturing a wood material

Abstract

A thin material with dimensional and mechanical stability based on wooden slats covered with a heat-meltable film, said slats being arranged to form a surface or a volume, bonded by hot-pressing said slats.

Description

[0001] P5723-PCT December 8, 2025

[0002] WOOD MATERIAL AND METHOD OF MANUFACTURING A WOOD MATERIAL

[0003] FIELD OF THE INVENTION

[0004] The present invention relates to a thin material, a three-dimensionally shaped object consisting of or comprising said thin material, and a method of manufacturing said thin material or three-dimensionally shaped object.

[0005] BACKGROUND OF THE INVENTION

[0006] In 2021, we created Arboloom (www.arboloom.com), a company that has developed a technology for producing disposable cups with a significantly lower carbon footprint than other methods available on the market today. The production of those cups is linked with two process-related constraints: the bonding of two separate subassemblies and the management of production waste and scrap of laminated veneer sheets.

[0007] The current Arboloom cups are made using two subassemblies formed each from a polymer-laminated wood veneer base material: the cup wall and the cup bottom. Ideally, one would also like to produce similar objects such as cups, bowls, plates, trays, packaging components, and the like using the same laminated wood veneer material, but out of a single part.

[0008] From day one, the use of production waste and scrap in the production and collection of used cups has been part of the circularity strategy. P5723-PCT December 8, 2025

[0009] - 2 -

[0010] Today, these materials are collected and transformed into particle board with partner companies. As Arboloom cups are coated with a bio-based polymer, the present inventors looked for ways to reuse this material.

[0011] It is an object of the present invention to overcome or at least mitigate at least one of the above-mentioned disadvantages of the prior art and, in particular, make use of wood waste and provide a thin, environmentally friendly and compostable wood material or wood panel that is mechanically and dimensionally very stable in a single step. It is a further object of the present invention to provide an object directly shaped from this material.

[0012] At least one of the objects are at least partially solved by a thin material, a three-dimensionally shaped object, and a method of manufacturing a thin material or a three-dimensional ly shaped object pursuant to the independent patent claims. Features which further develop the invention in an advantageous or alternative manner are described in the dependent claims.

[0013] SUMMARY OF THE INVENTION

[0014] The object is solved by a 3D-shaped object obtained by hot-pressing overlapping portions of a base material comprising or consisting of wood veneer laminated with thermoplastic material or a thin material obtained by hot-pressing overlapping portions of several elements of the base material together.

[0015] The object is in particular solved by a thin material with dimensional and mechanical stability based on wooden slats covered with a heat-meltable film. The wooden slats are arranged to form a surface or volume, i.e. the thin material may be flat or 3D shaped. The wooden slats are bonded by hot-pressing. In an alternative, the thin material is based on a single sheet of wood veneer comprising the heat-meltable film. The sheet is arranged to form a surface or volume, and hot-pressed. P5723-PCT December 8, 2025

[0016] - 3 -

[0017] In embodiments, the sheet overlaps, in particular with itself, to form at least one overlap area. The sheet is bonded by hot-pressing, in particular with itself, in the at least one overlap area by the heat-meltable film to form the surface or volume.

[0018] In embodiments, the slats are wood veneer.

[0019] In the context of the present invention, the term “thin” means in particular a thickness of 0.2 mm to 3 mm, in particular 1 mm to 3 mm or 0.4 mm to 2 mm.

[0020] In the context of the present invention, the term “wood veneer” means in particular wood veneer produced in a rotary lathe or as half round sliced veneer. In a rotary lathe, the wood is turned against a blade and peeled off in one continuous or semi-continuous roll. This gives the veneer a regular structure, with the grain of the wood, or grain direction, aligned with the plane of the veneer. This in turn makes it possible that channels in the wood that are designed to transport water are also aligned with the plane of the veneer. Furthermore, rotary cutting returns a high yield. Especially for thin veneer, the wood veneer is cut in the direction of the fibre, like for the planning of wood. Wood veneer produced as half round sliced veneer has a similar effect as for rotary cut veneer.

[0021] In the context of the present invention, the term “film” can in particular refer to a coating or a laminated foil.

[0022] The present inventors discovered a simple process starting with coated or laminated wood veneer instead of veneer and adhesive that involves taking strips of waste - or slats - and placing them in different orientations under an industrial press where, under high pressure and heat, the layers of waste are laminated into a single sheet bound by the coating, which has melted and solidified. Thanks to the crosswise arrangement of the strips, the material has dimensional and mechanical stability in multiple directions. In particular, strips that overlap in all directions to create a closed surface show P5723-PCT December 8, 2025

[0023] - 4 -

[0024] stability in all axes. The slats may be long, e.g. up to 1 meter in length, for excellent strength. Alternatively, a single sheet of wood veneer can be used instead of slats hot-pressed into a sheet. Surprisingly, the inventors found that a single sheet of wood veneer with slits or cutouts is even better suited to being formed into a three-dimensional object than a thin material made from a plurality of slats that have been hot-pressed together. In both alternatives, the thin material is foldable and malleable, allowing it to be formed into a three-dimensional shape. Moreover, the thin material is compostable because the base material is only wood and a compostable film.

[0025] This process could be done for several life cycles by shredding and reconstructing sheets made from the base material. At the end of its life or at any intermediate stage, the material can be returned to the biological cycle through composting.

[0026] This technology could be used to form thin boards, thin panels, plates, bowls and other shapes.

[0027] In embodiments, the slats are wood veneer. The heat-meltable film comprises a thermoplastic polymer. The heat-meltable film is arranged on at least a portion of a first side of the wood veneer.

[0028] In embodiments, the heat-meltable film is arranged only on the first side of the wood veneer. This saves on heat-meltable film.

[0029] In embodiments, the heat-meltable film is arranged on at least a portion of a second side of the wood veneer facing away from the first side.

[0030] In embodiments, the wood veneer has a veneer thickness of 0.2 mm to 1,0 mm. In particular, the wood veneer may have a veneer thickness between 0,3 mm and 0,6 mm. P5723-PCT December 8, 2025

[0031] - 5 -

[0032] With regard to a differentiation between hard wood and soft wood, there exist two general types of woody trees:

[0033] • Gymnosperms (seed plants not flowering), being coniferous (females bearing ovulate cones that release unenclosed seeds at maturity), usually evergreen (gradually shedding foliage, green foliage throughout year), known as softwoods (nonporous, wood typically lighter & softer), with needle-like or scale-like leaves. Examples are: firs, spruces, pines.

[0034] • Angiosperms (flowering seed plants), being fruit-bearing (enclosing seeds within), usually deciduous (seasonally shedding all foliage, no foliage for part of year), known as hardwoods (wood structure porous & more complex, wood generally harder), with broad leaves. Examples are: hickories, maples, oaks.

[0035] In embodiments, the wood veneer consists of or comprises hard wood or soft wood. The hard wood may in particular be selected from the group consisting of maple wood, birch wood, poplar wood, beech wood, ash wood, oak, wood, walnut wood. The soft wood may in particular be pine wood.For thin veneer, hard wood is preferable to coniferous woods. For food-contact applications, non-coniferous woods may be preferred. This is because resin present in wood of coniferous trees may disperse into substances such as beverages or foods.

[0036] In embodiments, the thermoplastic polymer is selected from the group consisting of polyethylene (PE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), polyethylene terephthalate (PET), ethylene-vinyl acetate (EVA), polyvinyl chloride (PVC), polyvinyl acetate (PVAC), ethylene vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), polypropylene (PP), a biopolyester, in particular a polyhydroxyalkanoate (PHA), a bio-based material, a biodegradable material, or a combination thereof. The bio-based or biodegradable material may, for example, be selected from polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), lignin and starch blends comprising thermoplastic starch and a biodegradable P5723-PCT December 8, 2025

[0037] - 6 -

[0038] polyester, polyesteramide, polyurethane, or polyvinyl alcohol. Specific examples of bio-based or biodegradable materials are ecovio® or Mater-Bi®.

[0039] In embodiments, the thin material comprises at least one through hole in the wood veneer, in particular located at the end of a slit or cutout as described in further detail with the blanks hereinafter. The at least one through hole helps to avoid tearing of the wood veneer during forming. The through holes may be closed with the thermoplastic polymer once the object is formed in order to render the thin material watertight. Alternatively, or in addition, at least some of the through holes may not be closed with the thermoplastic polymer in order to allow liquids to flow through the thin material, for example in a sieve, or for other purposes such as decrease of composting time.

[0040] In embodiments, the thin material is watertight.

[0041] In embodiments, the slats are arranged in the thin material such that at least a first layer and a second layer of the slats are bonded together by hot-pressing, wherein a predominant fiber orientation in the first layer runs at an angle to a predominant fiber orientation in the second layer. The predominant fiber orientation in the first layer may in particular run at an angle of approximately 90° relative to the predominant fiber orientation in the second layer.

[0042] Although the thin material - either due to the overlapping slats or due to the sheet overlapping itself - has a higher thickness locally in the overlap areas due to the increased number of layers, this difference in thickness is reduced by the hot-pressing.

[0043] As will be understood by the person skilled in the art, a thin material comprising a plurality of hot-pressed slats on the one hand and a single sheet on the other hand are essentially interchangeable alternatives. Accordingly, a method of manufacturing a three-dimensionally shaped object as disclosed herein may either start from hot-pressing slats into a sheet-like thin material or from a single sheet of wood veneer. P5723-PCT December 8, 2025

[0044] - 7 -

[0045] In embodiments, a thickness of the thin material in the at least one overlap area, measured perpendicularly between two opposite faces of the thin material, is at least 10%, preferably at least 25%, more preferably at least 50% less than the sum of the individual thicknesses of the thin material layers stacked in the at least one overlap area. This means that the thin material or the three-dimensionally shaped objects made therefrom have a more homogeneous thickness than the starting material, i.e. the overlapped slats or sheet, before hot-pressing.

[0046] In embodiments, the thickness of the thin material is substantially uniform across substantially the entire thin material. Such thin material, or three-dimensionally shaped object made from it, has a particularly uniform feel and therefore high-quality appearance.

[0047] In the context of the present invention, the term “substantially uniform across substantially the entire thin material” means that the thickness of the thin material is largely constant across the thin material, in particular that the thickness of the thin material deviates no more than 80%, preferably no more than 50%, relative to an average thickness of the thin material, preferably across at least 70% of the thin material. In other words, for a deviation in thickness of 80% and an average thickness of the thin material x, locally the thickness of the thin material can range from 0.2*x to 1.8*x.

[0048] In embodiments, the thin material is in the form of a blank comprising a pre-defined outer contour. The blank comprises at least one slit arranged in a volume enclosed by a convex hull of the blank. Alternatively, or in addition, the blank comprises at least one cutout arranged in the volume enclosed by the convex hull of the blank. P5723-PCT December 8, 2025

[0049] - 8 -

[0050] In the context of the present invention, the term “cutout” means that material has been removed from the blank so that the resulting edges of the adjacent sections no longer touch each other. The cutout can have any shape, in particular selected from a triangle, a partial circle, or a rectangle.

[0051] As commonly understood in the art, the convex hull of a set of points is the smallest convex set containing the points.

[0052] In embodiments, the pre-defined outer contour of the blank is a free-form curve.

[0053] In embodiments, the blank comprises at least one through hole arranged at an end of the at least one slit. Alternatively, or in addition, the blank comprises at least one through hole arranged at an end of the at least one cutout. A width of the through hole is larger than a width of the slit or cutout adjacent to the through hole. This helps to avoid tearing of the blank at the end of the slit or cutout. The at least one through hole is preferably closed by the heat-meltable film thermoplastic polymer during forming, i.e. hot-pressing, the blank into the three-dimensionally shaped object. However, the blank may comprise at least one through hole that is not arranged at an end of the at least one slit or cutout and that is not closed by the heat-meltable film thermoplastic polymer during forming, i.e. hot-pressing, the blank into the three-dimensionally shaped object.

[0054] In embodiments, the blank comprises at least one fold feature facilitating folding of the blank about said fold feature. The at least one fold feature may in particular be at least one creasing line. The fold feature locally reduces the radius of curvature of the folded blank compared to a fold without fold feature.

[0055] The object is further solved with a three-dimensionally shaped object consisting of or comprising the thin material according to any one of the embodiments disclosed herein. P5723-PCT December 8, 2025

[0056] - 9 -

[0057] In embodiments, the three-dimensionally shaped object is composed of at least two parts consisting of or comprising the thin material as disclosed herein. The at least two parts each comprise at least one slit arranged in a volume enclosed by a convex hull of the respective part. Alternatively, or in addition, the at least one slit may open into an outer contour of the respective part. The at least two parts are connected to each other such that the slits of the at least two parts run at an angle to each other, for example at an angle of approximately 90°. The three dimensionally shaped object may, in particular, be composed of a first thin material and a second thin material as disclosed herein. The at least two parts may, in particular, be connected to each other by hot-pressing. The plurality of slits allow each part to be pre-formed more easily in three dimensions before hot-pressing, making it easier to assemble the three-dimensionally shaped object from the at least two parts.

[0058] In embodiments, the three-dimensionally shaped object is composed of at least two parts consisting of or comprising the thin material as disclosed herein, wherein one of the at least two parts protrudes from an outer envelope defined by the remainder of the at least two parts of the three-dimensionally shaped object. The protruding part provides additional functionality to the three-dimensionally shaped object, for example in the form of a handle for a cup or a rim of a tray.

[0059] In embodiments, one or both of the at least two parts comprises a plurality of slits arranged in the volume enclosed by the convex hull of the respective part. The plurality of slits may in particular be selected from parallelly oriented slits, non-parallel slits, equally long slits, differently long slits, equally spaced slits, unequally spaced slits, straight slits, non-straight slits, and combinations thereof.

[0060] In embodiments, the three-dimensionally shaped object is selected from the group consisting of a container for food, a packaging element, a tray, a plate, a flower pot, a container for beverages. P5723-PCT December 8, 2025

[0061] - 10 -

[0062] The object is further solved by a method of manufacturing a thin material or a three-dimensionally shaped object as disclosed herein. The method comprises the steps of:

[0063] Providing a base material consisting of a wood veneer with an applied heat- meltable film; and

[0064] Arranging the base material on a plate or 3-D mold and hot-pressing.

[0065] In embodiments, the heat-meltable film comprises a thermoplastic polymer. The heat-meltable film is applied to at least a portion of a first side of the wood veneer. In embodiments, the heat-meltable film is applied only to the first side of the wood veneer.

[0066] In embodiments, the heat-meltable film is applied to at least a portion of a second side of the wood veneer facing away from the first side.

[0067] In embodiments, the heat-meltable film is applied to the entire first side and the entire second side of the wood veneer.

[0068] In embodiments, a thickness of the heat-meltable film is between 10 μm and 200 μm.

[0069] In embodiments, the heat-meltable film is applied to the wood veneer by at least one application technique selected from the group consisting of laminating, spraying, painting, printing.

[0070] In embodiments, the wood veneer has a veneer thickness of 0.2 mm to 1 mm. In particular, the wood veneer has a veneer thickness between 0.3 mm and 0.6 mm.

[0071] In embodiments, the wood veneer consists of or comprises hard wood or soft wood. The hard wood may in particular be selected from the group consisting of maple wood, birch wood, poplar wood, beech wood, ash wood, oak, wood, walnut wood. The soft wood may in particular be pine wood. P5723-PCT December 8, 2025

[0072] - 11 -

[0073] In embodiments, the base material is a single sheet of wood veneer comprising the heat-meltable film. In such embodiments, the method further comprises the steps of:

[0074] Creating a blank from the base material, the blank comprising a pre-defined outer contour and at least one of at least one slit and at least one cutout arranged in a volume enclosed by a convex hull of the blank;

[0075] Overlapping the blank, in particular with itself, to form at least one overlap area;

[0076] Hot-pressing and bonding the blank, in particular to itself, in the at least one overlap area by the heat-meltable film.

[0077] In embodiments, the method further comprises the steps of:

[0078] Cutting the base material into slats;

[0079] - Arranging the slats on a plate or 3-D mold and hot-pressing them to bond the slats together.

[0080] In embodiments, the wood veneer has a veneer thickness of 0.1 mm to 0.6 mm. The heat-meltable film is applied to the wood veneer by laminating. The heat-meltable film is a bio-based and compostable heat-meltable film with a film thickness of 0.05 mm. The wood veneer is laminated with the heat-meltable film on both sides. The base material is cut into slats with a width of 10 mm to 30 mm and a length of 200 mm to 1000 mm. Hot-pressing the slats is performed at 150 °C for 20 s to 30 s at a pressure between 5 N / mm2and 20 N / mm2.

[0081] In embodiments, the slats are arranged on the plate or 3-D mold such that at least a first layer and a second layer of the slats are bonded together by hot-pressing, wherein a predominant fiber orientation in the first layer runs at an angle relative to a predominant fiber orientation in the second layer. The angle may in particular be approximately 90°, P5723-PCT December 8, 2025

[0082] - 12 -

[0083] In embodiments, the method further comprises a step of creating a blank from the bonded slats. The blank comprises a pre-defined outer contour. The blank further comprises at least one slit arranged in a volume enclosed by the convex hull of the blank. Alternatively, or additionally, the blank further comprises at least one cutout arranged in the volume enclosed by the convex hull of the blank.

[0084] In embodiments, the pre-defined outer contour of the blank is a free-form curve.

[0085] In embodiments, the blank comprises at least one through hole arranged at an end of the at least one slit. Alternatively, or additionally, the blank comprises at least one through hole arranged at an end of the at least one cutout. A width of the through hole is larger than a width of the slit or cutout adjacent to the through hole.

[0086] In embodiments, at least one of the pre-defined outer contour, the at least one slit, the at least one cutout and the at least one through hole is provided by cutting or by diecutting. Cutting may, in particular, be effected by laser cutting or waterjet cutting.

[0087] In embodiments, the blank comprises at least one fold feature facilitating folding of the blank about said fold feature. The at least one fold feature may, in particular, be at least one creasing line.

[0088] In embodiments, the method further comprises a step of forming the blank into a three-dimensionally shaped object. Forming of the blank into the three-dimensionally shaped object may, in particular, be effected by hot-pressing. In the step of forming, a plurality of adjacent blank sections, which are separated from one another in the blank by the at least one slit or by the at least one cutout, are at least partially overlapped with one another to form at least one overlap area in the three-dimensionally shaped object. P5723-PCT December 8, 2025

[0089] - 13 -

[0090] In embodiments, the step of forming the blank into the three-dimensionally shaped object is carried out in a forming tool comprising at least one folding aid for controlling an overlapping sequence of a first section and a second section of the plurality of adjacent blank sections in the three-dimensionally shaped object. The at least one folding aid may in particular be selected from the group consisting of at least one retractable pin, at least one air flow, at least one vacuum suction point, and combinations thereof.

[0091] In embodiments, the method further comprises a step of applying an additional layer to the blank either before forming the blank into the three-dimensionally shaped object, in the forming tool, or after forming the blank into the three-dimensionally shaped object in the forming tool. The additional layer may in particular be selected from a second heat-meltable film, a reinforcing film, a sheet of wood veneer comprising a heat-meltable film.

[0092] In embodiments, the reinforcing film is for mechanical reinforcement of the wood veneer, for example another wood veneer or plywood. The wood veneer or plywood may be at least partially, in particular fully covered with a heat-meltable film, in particular as disclosed herein.

[0093] In embodiments, the additional layer is a second heat-meltable film, wherein the second heat-meltable film is applied to at least a portion of the blank. The second heat-meltable film comprises a second thermoplastic polymer. The second heat-meltable film may, in particular, be applied in the at least one overlap area.

[0094] In embodiments, a thickness of the second heat-meltable film is between 10 μm and 200 μm. P5723-PCT December 8, 2025

[0095] - 14 -

[0096] In embodiments, the second heat-meltable film is applied to the blank by at least one application technique selected from the group consisting of laminating, spraying, painting, printing.

[0097] In embodiments, at least one of the thermoplastic polymer and the second thermoplastic polymer is selected from the group consisting of polyethylene (PE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), polyethylene terephthalate (PET), ethylene-vinyl acetate (EVA), polyvinyl chloride (PVC), polyvinyl acetate (PVAC), ethylene vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), polypropylene (PP), a biopolyester, in particular a polyhydroxyalkanoate (PHA), a bio-based material, a biodegradable material, or a combination thereof. The bio-based or biodegradable material may, for example, be selected from polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), lignin and starch blends comprising thermoplastic starch and a biodegradable polyester, polyesteramide, polyurethane, or polyvinyl alcohol. Specific examples of bio-based or biodegradable materials are ecovio® or Mater-Bi®.

[0098] In embodiments, in the step of forming, the blank is connected to at least one further part consisting of or comprising the thin material as disclosed herein. The object is further solved by a product obtained or obtainable by a method according to any one of the embodiments disclosed herein.

[0099] Unless otherwise specified, individual or several embodiments disclosed hereinbefore can be combined with one another.

[0100] BRIEF DESCRIPTION OF THE DRAWINGS

[0101] The invention will be explained in more detail using the examples shown in the following drawings: P5723-PCT December 8, 2025

[0102] - 15 -

[0103] Fig. 1: Slats 3 of pre-laminated wood veneer waste;

[0104] Fig. 2: Preparation of the arrangement of the wooden slats 3;

[0105] Fig. 3: Pressing in a hot press 20;

[0106] Fig. 4: Sheet of material 10;

[0107] Fig. 5: Random arrangement;

[0108] Fig. 6: Example of a 3D object 100 manufactured from a random arrangement;

[0109] Fig. 7: Organized arrangement;

[0110] Fig. 8: Example of a thin panel 10 manufactured from an arrangement of organized strips;

[0111] Fig. 9a: Example of a blank 11 for manufacturing a round bowl;

[0112] Fig. 9b: The blank 11 shown in Fig. 9a, with overlap areas 6 indicated;

[0113] Fig. 10a: Example of a blank 11 with fold features 16 for manufacturing a square plate;

[0114] Fig. 10b: A plate 100 manufactured from the blank 11 shown in Fig. 10a;

[0115] Fig. 11a: Example of a blank 11 for manufacturing a triangular tray; P5723-PCT December 8, 2025

[0116] - 16 -

[0117] Fig. 11b: A triangular tray 100 manufactured from the blank 11 shown in Fig.

[0118] 11a;

[0119] Fig. 12a: Example of a blank 11 for manufacturing an open frustum of a cone;

[0120] Fig. 12b: An open frustum of a cone 100 manufactured from the blank 11 shown in Fig. 12a;

[0121] Fig. 13a: Example of a blank 11 for manufacturing a cone;

[0122] Fig. 13b: A cone 100 manufactured from the blank 11 shown in Fig. 13a;

[0123] Fig. 14a: Example of a blank 11 for manufacturing a narrow cone;

[0124] Fig. 14b: A narrow cone 100 manufactured from the blank 11 shown in Fig. 14a;

[0125] Fig. 15a: Example of a blank 11 for manufacturing a bowl;

[0126] Fig. 15b: A bowl 100 manufactured from the blank 11 shown in Fig. 15a;

[0127] Fig. 16a: Example of two blank parts 101, 102 for manufacturing a bowl;

[0128] Fig. 16b: Assembly of the two blank parts 101, 102 shown in Fig. 16a after forming;

[0129] Fig. 16c: A bowl 100 manufactured from the formed blank parts 101, 102 shown in Fig. 16b; P5723-PCT December 8, 2025

[0130] - 17 -

[0131] Fig. 17a: Example of two blank parts 101, 102 for manufacturing a tray with a rim;

[0132] Fig. 17b: A tray 100 manufactured from the blank parts 101, 102 shown in Fig.

[0133] 17a;

[0134] Fig. 18a: Example of a blank 11 for manufacturing a freeform bowl;

[0135] Fig. 18b: A freeform bowl 100 manufactured from the blank 11 shown in Fig.

[0136] 18a;

[0137] Fig. 19a: A forming tool 20 with a folding aids 21 in an open state;

[0138] Fig. 19b: The forming tool shown in Fig. 19a in a closed state;

[0139] Fig. 20: Schematic diagram of an embodiment of a method for manufacturing a three-dimensionally shaped object 100 consisting of a thin material 10 as disclosed herein.

[0140] DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0141] The steps in the manufacturing process are shown in Figures 1-4.

[0142] The base material is a 0.1 to 0.6 mm thick wood veneer, for example birch, laminated with a 0.05 mm thick bio-based and compostable film on both sides. The film can be, for example, a PHA (polyhydroxyalkanoate). PHAs are polyesters biosynthesised by a fed bacterium. The laminated veneer is cut into small strips - slats 3 - 10 to 30 mm wide and 200 to 1000 mm long, which can have different shapes, including rounded shapes, as shown in Figure 1. These strips can also be waste from the production of P5723-PCT December 8, 2025

[0143] - 18 -

[0144] Arboloom cups. The slats 3 are placed on a plate, as shown in Figure 2, or a 3-D mold and pressed in a hot press, as shown in Figure 3, at 150°C for 20 to 30 seconds, depending on the number of layers.

[0145] The temperature must be close to the melting point of the polymer used for lamination, typically + / - 20 °C and preferably + / - 10 °C. The pressure is between 5 N / mm2and 20 N / mm2. This pressure is high enough to plastically compress the wood to obtain a nice flat surface. In principle, all types of wood can be used, whether scrap wood or standard veneer. The following species have been tested: birch, beech, ash, poplar, maple, pine, oak, walnut.

[0146] Certain textures can be added to the mold, and these patterns will be pressed into the wood veneer.

[0147] Figure 4 shows the thin material 10 obtained after hot-pressing and bonding the slats 3 of wood veneer laminated with the bio-based and compostable film on both sides, i.e. a first side 3a and a second side 3b of the wood veneer facing away from the first side 3 a, together.

[0148] Figure 5 shows a thin material 1 consisting of a plurality of wooden slats 3 covered with a heat-meltable film. The wooden slats 3 are arranged in a random orientation and bonded together by hot-pressing to form a surface.

[0149] Figure 6 shows an example of a three-dimensionally shaped object 100 having a plate shape. The three-dimensionally shaped object 100 is obtainable from the thin material 10 shown in Figure 1 by creating a circular blank from the thin material 10, e.g. using a punching tool on the thin material 10, and forming the blank into the plate shape, e.g. using a forming tool. P5723-PCT December 8, 2025

[0150] - 19 -

[0151] Figures 7 and 8 show a thin material 10 and an example of a thin panel 100 manufactured from an organized arrangement of slats 3, respectively. The slats 3 are arranged in the thin material 10 such that a plurality of slat layers including a first layer of slats 3’ and a second layer of slats 3” are arranged crosswise and interwoven in a checkerboard pattern. A predominant fiber orientation in the first layer 3’ runs at an angle of approximately 90° relative to a predominant fiber orientation in the second layer 3”. The slats 3 are subsequently bonded together by hot-pressing to form the thin material 10, and the edges of the thin material 10 may subsequently be trimmed to obtain the thin panel 100.

[0152] Figure 9a shows a thin material 10, based on a sheet of wood veneer comprising a heat-meltable film, in the form of a blank 11. The blank 11 comprises a circular outer contour 12 defining the convex hull 15 of the blank 11. The blank 11 further comprises eight slits 13 arranged in the volume enclosed by the convex hull 15, wherein the eight slits 13 divide the blank 11 into neighboring blank sections Ila, 11b, respectively. Figure 9b shows the blank 11 shown in Figure 9a, wherein the thin material 10 overlaps with itself to form eight overlap areas 6, in each of which the neighboring blank sections Ila, lib of the blank 11 overlap. The thin material 10 is bonded to itself by hot-pressing in the overlap areas 6 by the heat-meltable film, resulting in a bowlshaped object made of the thin material 10.

[0153] Figure 10a shows an example of a blank 11 based on a single sheet 4 of wood veneer covered with a heat-meltable film. The blank 11 comprises, in addition to four slits 13, creasing lines 16. The creasing lines 16 are indicated by the dashed lines in Figures 10a, 10b and act as fold features. Moreover, the blank 11 comprises four through holes 5, each of which are arranged at an end of the four slits 13. A width of the through holes 5 is larger than a width of the slits 13 adjacent to the respective through hole 5. The blank 11 is for manufacturing a square plate- shaped object 100. As shown in Figure 10b, the sheet 4 overlaps with itself to form four overlap areas 6 and is bonded to itself by the heat-meltable film by hot-pressing the sheet 4 at least in the overlap areas 6. The overlap areas 6 are shown as hatched areas in Figure 10b. The through P5723-PCT December 8, 2025

[0154] - 20 -

[0155] holes may in particular be closed during the overlapping and hot-pressing steps and sealed by the meat-meltable film to render the formed volume essentially watertight.

[0156] Figure 1 la shows an example of a blank 11 for manufacturing a triangular tray. The blank 11 is based on a single sheet 4 of wood veneer covered with a heat-meltable film and comprises a triangular outer contour 12 with rounded comers. The outer contour 12 defines the convex hull 15 of the blank 11. The blank 11 further comprises three slits 13 arranged in the volume enclosed by the convex hull 15, wherein the three slits 13 divide the blank 11, viewed in a circumferential direction along the outer contour 12, into three blank sections Ila, lib, lie, wherein blank sections Ila and lib, lib and 11c, and 11c and 1 la are neighboring blank sections, i.e. arranged adjacent to each other. The blank 11 further comprises three through holes 5, each of which is arranged at one of the slits 13, namely at the radially inward-facing end of the respective slits 13. As apparent from Figure Ila, a width of the respective through holes 5 is larger than a width of the corresponding slit 13 adjacent to the through hole 5. The holes 5 are for preventing tearing of the thin material or blank 11 when overlapping and hot pressing. Figure 11b shows the triangular tray 100 manufactured from the blank 11 shown in Figure Ila, wherein the sheet 4 overlaps with itself to form three overlap areas 6 and is bonded to itself by the heat-meltable film by hot-pressing the sheet 4 at least in the three overlap areas 6.

[0157] Figure 12a shows an example of a blank 11 with a circular outer contour 12, a central through hole 5, and a single slit 13 arranged in the convex hull 15 of the blank 11. The blank 11 is based on a single sheet 4 of wood veneer covered with a heat-meltable film. Figure 12b shows a frustum of a cone 100 with a central opening, i.e. through hole 5, manufactured from the blank 11 shown in Figure 12a. To this end, the sheet 4 is arranged to form a volume by overlapping the sheet 4 with itself to form an overlap area 6 and bonding the sheet 4 to itself by the heat-meltable film by hot-pressing the sheet 4 at least in the overlap area 6. The overlap area 6 is shown as a hatched area in Figure 12b. P5723-PCT December 8, 2025

[0158] - 21 -

[0159] Figure 13a shows an example of a blank 11 with a circular outer contour 12 and a single slit 13 arranged in the convex hull 15 of the blank 11. The blank 11 comprises a single through hole 5 arranged at an end of slit 13, in a center of the circular blank 11, wherein a width of the through hole 5 is larger than a width of the slit 13 adjacent to the through hole 5. The blank 11 is based on a single sheet 4 of wood veneer covered with a heat-meltable film. Figure 13b shows a cone 100 manufactured from the blank 11 shown in Figure 13a. To this end, the sheet 4 is arranged to form a volume by overlapping the sheet 4 with itself to form an overlap area 6 and bonding the sheet 4 to itself by the heat-meltable film by hot-pressing the sheet 4 at least in the overlap area 6. The overlap area 6 is shown as a hatched area in Figure 13b. The through hole 5 may in particular be closed during the overlapping and hot-pressing steps and sealed by the meat-meltable film to render the formed volume, i.e. cone, essentially watertight.

[0160] Figure 14a shows an example of a blank 11 with a circular sector or pie-shaped outer contour 12 corresponding to the convex hull 15 of the blank 11. The blank 11 is based on a single sheet 4 of wood veneer covered with a heat-meltable film. Figure 14b shows a narrow cone 100 manufactured from the blank 11 shown in Figure 14a. by arranging the sheet 4 to form a volume, i.e. by overlapping the sheet 4 with itself to form an overlap area 6, and bonding the sheet 4 to itself by the heat-meltable film by hot-pressing the sheet 4 at least in the overlap area 6. The overlap area 6 is shown as a hatched area in Figure 14b.

[0161] Figure 15a shows an example of a blank 11 with a single spiral-shaped slit 13 separating radially adjacent blank sections. The blank 11 is based on a single sheet 4 of wood veneer laminated with a heat-meltable film and has a spiral-shaped outer contour 12 defining a convex hull 15 of the blank 11, wherein the single slit 13 is arranged in the volume enclosed by the convex hull 15. Figure 15b shows a bowl manufactured from the blank 11 shown in Figure 15a, wherein the blank 11 overlaps with itself to form a contiguous overlap area 6 in which the adjacent blank sections P5723-PCT December 8, 2025

[0162] - 22 -

[0163] overlap. The blank 11 is bonded to itself by the heat-meltable film by hot-pressing the sheet 4 in the overlap area 6, resulting in a bowl-shaped object 100.

[0164] Figure 16a shows an example of two blank parts 101, 102 for manufacturing a bowl. Each blank part 101, 102 features a circular outer contour 12 and a plurality of parallelly oriented slits 13, which are arranged in the volume enclosed by the convex hull 15 of the respective blank part 101, 102. The slits 13 give the respective blank parts 101, 102 better deformability, in particular bendability, in a preferred direction perpendicular to the slits 13. Optionally, the blanks have a round creasing line in the form of a circle in their center. The two blank parts 101, 102 may be connected to each other such that the slits 13 of the two blank parts 101, 102 run at an angle to each other. For example, the blank parts 101, 102 shown in Figure 16a could be connected to each other in such a way that the slits 13 of the first blank part 101 run at an angle of approximately 90° to the slits 13 of the second blank part 102, as shown in Figure 16b. This facilitates the assembly and shaping of the blank parts 101, 102 into a three-dimensionally shaped object 100. In addition, in areas where slits 13 overlap in the three-dimensionally shaped object 100, passage openings may remain, so that the three-dimensionally shaped object has though holes 5 like a sieve, as shown in Figure 16c. The round creasing lines provide a smaller curvature radius locally and make the bottom of the bowl essentially flat. However, it is also conceivable that the flow of material in the heat-meltable films during hot pressing closes these through holes, or that at least one of the two blank parts 101, 102 has an additional layer of material to close the through holes more reliably and make the three-dimensionally shaped object waterproof.

[0165] Figure 17a shows an example of two blank parts 101, 102 for manufacturing an assembled tray. Each of the two blank parts 101, 102 is based on a single sheet of wood veneer 4 covered with a heat-meltable film. One of the blank parts 101 comprises four cut outs 13 located in the four comers of the blank part. The other blank part 102 comprises four slits 13, also located in the four comers of the blank part. In addition, each of the two blank parts 101, 102 comprises creasing lines 16, indicated by the P5723-PCT December 8, 2025

[0166] - 23 -

[0167] dashed lines in Figures 17a, 17b, acting as fold features. The blank parts may be assembled and hot-pressed as disclosed herein to form the three-dimensionally shaped tray 100 shown in Figure 17b. The overlap areas 6 in which the two parts 101, 102 overlap with itself and / or with the other part are shown as hatched areas in Figure 17b.

[0168] Figure 18a shows an example of a blank 11 with a freeform outer contour 12 and a plurality of slits 13 arranged in the convex hull 15 of the blank 11. The blank 11 is based on a single sheet 4 of wood veneer covered with a heat-meltable film. Figure 18b shows a bowl 100 manufactured from the blank 11 shown in Figure 18a. To this end, the sheet 4 is arranged to form a volume by overlapping the sheet 4 with itself to form a plurality of overlap areas 6 and bonding the sheet 4 to itself with the heat-meltable film by hot-pressing the sheet 4 at least in the overlap areas 6. The overlap areas 6 are shown as a hatched areas in Figure 18b.

[0169] Figure 19a shows a forming tool 20 with two folding aids 21 in an open state, used in a step of forming a blank 11 into a three-dimensionally shaped object 100, as shown in Figure 19b. In the step of forming, a plurality of adjacent blank sections, which are separated from one another in the blank 11 by at least one slit or cutout, are at least partially overlapped with one another to form at least one overlap area in the three-dimensionally shaped object 100. In order to determine an overlap sequence of the plurality of adjacent blank sections, the folding aids 21, for example retractable pins, of the forming tool 20 are extended to push against blank sections Ila, 11c, whereas the remaining blank sections (not shown in Figure 19a, 19b) are not contacted by the folding aids 21. This way, when the forming tool 20 is closed, the remaining blank sections slide under blank sections Ila and 11c, respectively.

[0170] Figure 20 shows a schematic diagram of an embodiment of a method for manufacturing a thin material 10 as disclosed herein, and a three-dimensionally shaped object 100 consisting of said thin material 10. In a first step a), a base material 1 is provided. The base material 1 consists of wood veneer 7 with an applied heat-meltable P5723-PCT December 8, 2025

[0171] - 24 -

[0172] film 2. The heat-meltable film 2 comprises a thermoplastic polymer and can be applied on the wood veneer 7 as a coating, for example by spraying. In embodiments of the method where the base material 1 is a single sheet 4 of wood veneer, the method further comprises a step bl) of creating a blank 11 from the base material 1, i.e. from the single wood veneer sheet 4. The blank 11 comprises a pre-defined outer contour and at least one of at least one slit and at least one cutout arranged in a volume enclosed by a convex hull of the blank 11. In subsequent step cl), the blank 11 is overlapped, in particular with itself, to create at least one overlap area. In other embodiments of the method, the base material 1 provided in step a) is cut into slats 3 in step b2). In subsequent step c2), the slats 3 are arranged on a plate or 3-D mold in an overlapping manner. In all embodiments, the overlap areas of the blank 11 or the overlapping slats 3 are hot-pressed such that the overlap areas or the slats are bonded by the heat-meltable film 2 in step d), respectively, to provide thin material 10. The thin material 10 obtained after hot-pressing can already be the three-dimensionally shaped object 100. In embodiments in which the thin material 10 is flat or plate-shaped without a pre-defined outer contour, in particular obtained from a plurality of slats 3 hot-pressed together in step d), the method may comprise a further step e2) of creating a blank 11 from the thin material 10, i.e. from the bonded slats 3, wherein the blank 11 comprises a pre-defined outer contour and at least one of at least one slit and at least one cutout arranged in a volume enclosed by the convex hull of the blank 11. Subsequently, in step f2), the blank 11 is formed into a three-dimensionally shaped object 100 by at least partially overlapping a plurality of adjacent blank sections, which are separated from one another in the blank 11 by the at least one slit or by the at least one cutout, with one another to form at least one overlap area, and hot-pressing the overlap areas such that the overlap areas are bonded by the heat-meltable film 2.

[0173] Applications

[0174] 1. Sheets or shapes with wooden slats arranged in an uncontrolled manner (Figure 5). At least 4 layers of 0.5 mm thick slats. Thickness of the pressed sheet: 1-2 mm P5723-PCT December 8, 2025

[0175] - 25 -

[0176] Application: to create very stable reconstituted sheets or to form a three-dimensional object.

[0177] 2. Sheet or shape with isotropic characteristics, woven or non-woven (Figure 6). The slats are woven or placed in a controlled manner before being pressed. The wooden slats are woven in a regular or irregular pattern, or non-woven.

[0178] Application: as a highly stable sheet material, to form three-dimensional shapes or as a material comparable to a woven fibre surface. P5723-PCT December 8, 2025

[0179] - 26 -

[0180] List of reference numerals

[0181] 1 Base material

[0182] 2 Heat-meltable film

[0183] 2’ Second heat-meltable film

[0184] 3 Slat

[0185] 3a First side of slat

[0186] 3b Second side of slat

[0187] 3’ First slat layer

[0188] 3” Second slat layer

[0189] 4 Sheet

[0190] 4a First side of sheet

[0191] 4b Second side of sheet

[0192] 4’ First sheet

[0193] 4” Second sheet

[0194] 5 Through hole

[0195] 6 Overlap area

[0196] 7 Wood veneer

[0197] 10 Thin material

[0198] 10a Frist face of the thin material

[0199] 10b Second face of the thin material

[0200] 11 Blank

[0201] 11a First blank section

[0202] 11b Second blank section

[0203] 11c Third blank section

[0204] 11d Fourth blank section

[0205] lie Fifth blank section

[0206] 12 Outer contour

[0207] 13 Slit

[0208] 14 Cutout

[0209] 15 Convex hull of blank P5723-PCT December 8, 2025

[0210] - 27 -

[0211] 16 Fold feature

[0212] 20 Forming tool

[0213] 21 Forming aid

[0214] 100 Three-dimensionally shaped object 101 First part

[0215] 102 Second part

Claims

P5723-PCT December 8, 2025 - 28 -WHAT IS CLAIMED IS:1, A thin material (10) with dimensional and mechanical stability based on a single sheet (4) of wood veneer or wooden slats (3) covered with a heat-meltable film (2), said sheet (4) or slats (3) being arranged to form a surface or a volume, bonded by hot-pressing said sheet (4) or slats (3).

2. The thin material (10) according to claim 1, wherein the sheet (4) overlaps, in particular with itself, to form at least one overlap area (6) and is bonded, in particular to itself, by hot-pressing in the at least one overlap area (6) by the heat- meltable film (2) to form the surface or volume.

3. The thin material (10) according to claim 1, wherein the slats (3) are wood veneer.

4. The thin material (10) according to any one of claims 1 to 3, wherein the heat- meltable film (2) comprises a thermoplastic polymer, and wherein the heat-meltable film (2) is arranged on at least a portion of a first side (3a) of the slats (3) or on at least a portion of a first side (4a) of the sheet (4).5, The thin material (10) according to claim 4, wherein the heat-meltable film (2) is applied only to the first side (3a) of the slats (3) or to the first side (4a) of the sheet (4).

6. The thin material (10) according to claim 4 or 5, wherein the heat-meltable film (2) is arranged on at least a portion of a second side (3b) of the slats (3) or on at least aP5723-PCT December 8, 2025 - 29 -portion of a second side (4b) of the sheet (4), wherein the second side (3b, 4b) is arranged opposite to the respective first side (3a, 4a),7, The thin material (10) according to any one of claims 1 to 6, wherein the slats (3) or the sheet (4) have a thickness of 0.2 mm to 1.0 mm, in particular between 0.3 mm and 0.6 mm.8, The thin material (10) according to any one of claims 1 to 7, wherein the wood veneer consists of or comprises hard wood, in particular selected from the group consisting of maple wood, birch wood, poplar wood, beech wood, ash wood, oak, wood, walnut wood, or soft wood, in particular pine wood.9, The thin material (10) according to any one of claims 4 to 8, wherein the thermoplastic polymer is selected from the group consisting of polyethylene (PE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), polyethylene terephthalate (PET), ethylene-vinyl acetate (EVA), polyvinyl chloride (PVC), polyvinyl acetate (PVAC), ethylene vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), polypropylene (PP), a biopolyester, in particular a polyhydroxyalkanoate (PHA), a bio-based material, in particular polylactic acid (PLA), a biodegradable material, or a combination thereof.10, The thin material (10) according to any one of claims 1 to 9, wherein the thin material comprises at least one through hole (5) in the wood veneer.11, The thin material (10) according to any one of claims 1 to 10, wherein the thin material is watertight.P5723-PCT December 8, 2025 - 30 -12. The thin material (10) according to any one of claims 1 to 11, wherein the slats (3) are arranged in the thin material (10) such that at least a first layer (3’) and a second layer (3”) of the slats (3) are bonded together by hot-pressing, wherein a predominant fiber orientation in the first layer (3’) runs at an angle, in particular at an angle of approximately 90°, relative to a predominant fiber orientation in the second layer (3”).

13. The thin material (10) according to any one of claims 2 to 12, wherein a thickness of the thin material (10) in the at least one overlap area (6), measured perpendicularly between two opposite faces (10a, 10b) of the thin material (10), is at least 10%, preferably at least 25%, more preferably at least 50% less than a sum of the individual thicknesses of the thin material layers stacked in the at least one overlap area (6).

14. The thin material (10) according to any one of claims 1 to 13, wherein the thin material (10) is in the form of a blank (11) comprising a pre-defined outer contour (12) and at least one of at least one slit (13) and at least one cutout (14) arranged in a volume enclosed by a convex hull (15) of the blank (11).

15. The thin material (10) according to claim 14, wherein the outer contour (12) is a free-form curve.

16. The thin material (10) according to claim 14 or 15, wherein the blank (11) comprises at least one through hole (5) arranged at an end of the at least one slit (13) and / or at an end of the at least one cutout (14), wherein a width of the through hole (5) is larger than a width of the slit (13) or cutout (14) adjacent to the through hole (5).P5723-PCT December 8, 2025 - 31 -17. The thin material (10) according to any one of claims 14 to 16, wherein the blank (11) comprises at least one fold feature (16), in particular at least one creasing line, facilitating folding of the blank (11) about said fold feature (16).

18. A three-dimensionally shaped object (100) consisting of or comprising the thin material (10) according to any one of claims 1 to 17.

19. The three-dimensionally shaped object (100) according to claim 18, wherein the three-dimensionally shaped object (100) is composed of at least two parts (101, 102), wherein the at least two parts (101, 102) consist of or comprise the thin material (10) according to any one of claims 1 to 15, wherein the at least two parts (101, 102) each comprise at least one slit (13) arranged in a volume enclosed by a convex hull of the respective part (101, 102) and / or opening into an outer contour (12) of the respective part (101, 102), and wherein the at least two parts (101, 102) are connected to each other, in particular by hot-pressing, such that the slits (13) of the at least two parts (101, 102) run at an angle to each other.

20. The three-dimensionally shaped object (100) according to claim 18 or 19, wherein the three-dimensionally shaped object (100) is selected from the group consisting of a container for food, a container for beverages, a packaging element, a flower pot.

21. A method of manufacturing a thin material (10) according to any one of claims 1 to 17 or a three-dimensionally shaped object (100) according to any one of claims 18 to 20, the method comprising the steps:- Providing a base material (1) consisting of a wood veneer (7) with an applied heat- meltable film (2);P5723-PCT December 8, 2025 - 32 -- Arranging the base material (1) on a plate or 3-D mold and hot-pressing,22. The method according to claim 21, wherein the heat-meltable film (2) comprises a thermoplastic polymer, and wherein the heat-meltable film (2) is applied to at least a portion of a first side (3a, 4a) of the wood veneer.

23. The method according to claim 22, wherein the heat-meltable film (2) is applied only to the first side (3a, 4a) of the wood veneer.24, The method according to claim 22 or 23, wherein the heat-meltable film (2) is applied to at least a portion of a second side (3b, 4b) of the wood veneer facing away from the first side (3 a, 4a).25, The method according to any one of claims 22 to 24, wherein a thickness of the heat-meltable film (2) is between 10 μm and 200 μm.

26. The method according to any one of claims 21 to 25, wherein the heat-meltable film (2) is applied to the base material (1) by at least one application technique selected from the group consisting of laminating, spraying, painting, printing.27, The method according to any one of claims 21 to 26, wherein the wood veneer has a thickness of 0.2 mm to 1 mm, in particular between 0.3 mm and 0.6 mm.28, The method according to any one of claims 21 to 27, wherein the wood veneer consists of or comprises hard wood, in particular selected from the group consisting of maple wood, birch wood, poplar wood, beech wood, ash wood, oak, wood, walnut wood, or soft wood, in particular pine wood.P5723-PCT December 8, 2025 - 33 -29. The method according to any one of claims 21 to 28, wherein the base material (1) is a single sheet (4) of wood veneer, wherein the method further comprises the steps of:- Creating a blank ( 11 ) from the base material ( 1 ), the blank (11) comprising a predefined outer contour (12) and at least one of at least one slit (13) and at least one cutout (14) arranged in a volume enclosed by a convex hull (15) of the blank (11); - Overlapping the blank (11), in particular with itself, to create at least one overlap area (6);- Hot-pressing and bonding the blank (11), in particular to itself, in the at least one overlap area (6) by the heat-meltable film (2).30, The method according to any one of claims 21 to 28, further comprising the steps of:- Cutting the base material (1) into slats (3);- Arranging the slats (3) on a plate or 3-D mold and hot-pressing them to bond the slats (3) together.31, The method according to claim 30, wherein the wood veneer has a thickness of 0, 1 mm to 0,6 mm, wherein the heat-meltable film (2) is applied to the wood veneer by laminating, wherein the heat-meltable film (2) is a bio-based and compostable heat-meltable film with a film thickness of 0.05 mm, wherein the wood veneer is laminated with the heat-meltable film (2) on both sides of the wood veneer, wherein the base material is cut into slats (2) with a width of 10 mm to 30 mm and a length of 200 mm to 1000 mm, and wherein hot-pressing the slats is performed at 150 °C for 20 s to 30 s at a pressure between 5 N / mm2and 20 N / mm2.P5723-PCT December 8, 2025 - 34 -32. The method according to claim 30 or 31, wherein the slats (3) are arranged on the plate or 3-D mold such that at least a first layer (3’) and a second layer (3”) of the slats (3) are bonded together by hot-pressing, wherein a predominant fiber orientation in the first layer (3’) runs at an angle, in particular at an angle of approximately 90°, relative to a predominant fiber orientation in the second layer (3”).

33. The method according to any one of claims 30 to 32, further comprising a step of creating a blank (11) from the bonded slats, wherein the blank (11) comprises a predefined outer contour (12) and at least one of at least one slit (13) and at least one cutout (14) arranged in a volume enclosed by the convex hull (15) of the blank (11).

34. The method according to any one of claims 29 to 33, wherein the outer contour (12) is a free-form curve.

35. The method according to any one of claims 29 to 34, wherein the blank (11) comprises at least one through hole (5) arranged at an end of the at least one slit (13) and / or at an end of the at least one cutout (14), wherein a width of the through hole (5) is larger than a width of the slit (13) or cutout (14) adjacent to the through hole (5).

36. The method according to any one of claims 29 to 35, wherein at least one of the pre-defined outer contour (12), the at least one slit (13), the at least one cutout (14) and the at least one through hole (5) is provided by cutting, in particular by laser cutting or waterjet cutting, or by die-cutting.P5723-PCT December 8, 2025 - 35 -37. The method according to any one of claims 29 to 36, wherein the blank (11) comprises at least one fold feature (16), in particular at least one creasing line, facilitating folding of the blank (11) about said fold feature (16).

38. The method according to any one of claims 29 to 37, further comprising a step of forming, in particular molding, the blank (11) into a thiee-dimensionally shaped object (100), wherein, in the step of forming, a plurality of adjacent blank sections (Ila, 11b, 11c, l id, lie), which are separated from one another in the blank (11) by the at least one slit (13) or by the at least one cutout (14), are at least partially overlapped with one another to form at least one overlap area (6) in the three- dimensionally shaped object (100).

39. The method according to claim 38, wherein the step of forming is carried out in a forming tool (20) comprising at least one folding aid (21), in particular at least one retractable pin, at least one air flow and / or at least one vacuum suction point, for controlling an overlapping sequence of a first section (11a) and a second section (11b) of the plurality of adjacent blank sections (11a, 11b, 11c, 11d, 11e) in the thiee-dimensionally shaped object (100).

40. The method according to any one of claims 29 to 39, further comprising a step of applying an additional layer to the blank (11) either before or after the step of hot- pressing the blank (11) or in a forming tool used in the step of hot-pressing the blank (11).

41. The method according to claim 40, wherein the additional layer is a second heat- meltable film (2’), wherein the second heat-meltable film is applied to at least a portion of the blank (11), in particular in the at least one overlap area (6), andP5723-PCT December 8, 2025 - 36 -wherein the second heat-meltable film (2’) comprises a second thermoplastic polymer.

42. The method according to claim 41, wherein a t hickness of the second heat-meltable film (2’) is between 10 μm and 200 μm.

43. The method according to any one of claims 40 to 42, wherein the second heat- meltable film (2’) is applied to the blank (11) by at least one application technique selected from the group consisting of laminating, spraying, painting, printing.

44. The method according to any one of claims 22 to 43, wherein the thermoplastic polymer and / or the second thermoplastic polymer is selected from the group consisting of polyethylene (PE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), polyethylene terephthalate (PET), ethylene-vinyl acetate (EVA), polyvinyl chloride (PVC), polyvinyl acetate (PVAC), ethylene vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), polypropylene (PP), a biopolyester, in particular a polyhydroxyalkanoate (PHA), a bio-based material, in particular polylactic acid (PLA), a biodegradable material, or a combination thereof.

45. The method according to any one of claims 38 to 44, wherein, in the step of forming, the blank (11) is connected to at least one further (101, 102) part consisting of or comprising the thin material (10) according to any one of claims 1 to 17.

Images