Teen Innovators Aim to Remove Plastic from Shipping Boxes, Pitching Amazon and Home Depot

Teen Innovators Aim to End Plastic Shipping

City‑Born Trio Unveils Eco‑Friendly Packaging

Zhi Han Yao, Flint Mueller, and James Clare have developed a geometric, cardboard material called Kiriboard. Inspired by Japanese kirigami, they hope this design will replace toxic plastics and enable plastic‑free shipping worldwide.

Future‑Ready Solution

• Kiriboard’s folding patterns allow lightweight, sturdy shipping boxes.
• Plan to patent the invention and pitch to major shippers such as Amazon, FedEx, and the U.S. Postal Service.
• Target to partner with Home Depot for retail distribution.

Recognized by the Earth Prize

On April 8, the trio won the Earth Prize, placing them among seven outstanding teenage environmental projects globally. The award grants $12,500 for new equipment.

• They will purchase a CNC router to cut and test additional prototypes.
• They foresee spreading Kiriboard’s use to packaging cars, boxes, and reusable containers.

Teacher’s Vision

Environmental‑science teacher Jerry Citron told Business Insider that “something like this is the wave of the future.” His guidance helped shape the project’s mission toward a greener shipping industry.

Plastic-free shipping could change the world

Microplastics: An Invisible Global Crisis

Plastic packaging—whether Styrofoam, bottles or other goods—can release microscopic plastic fragments into homes and the environment.

From Oceans to Peaks: Where Microplastics Thrive

• Marine ecosystems and the upper reaches of Mount Everest
• Animal tissues and human blood
• Rain worldwide, drenching the planet

Health Implications of Microplastic Exposure

Researchers have linked microplastics to increased risks of heart attacks and strokes. Some scientists suspect these particles may also contribute to the recent surge of colon cancers among young adults.

Reevaluating Sustainable Packaging

“I never realized how big of a problem it was,” Yao shared with BI. “Companies have launched sustainable and greener initiatives, yet they haven’t fully replaced plastic packaging.”

Introducing the Kiriboard

The Kiriboard is crafted into lattice-like shapes that allow it to bend between an item and its box’s wall. These cuts provide a three-dimensional structure that makes the cardboard both sturdy and flexible, enabling it to absorb impact. The result is protection comparable to bubble wrap, but without the use of plastic.

Advantages of the Kiriboard System

• Resilient, three-dimensional support
• Flexible bending, reducing waste
• Impact absorption, protecting contents without plastic

Looking Ahead

As the global community continues to explore alternatives to conventional plastic packaging, the Kiriboard offers an innovative solution that blends structure, flexibility, and sustainability.

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Featured Topics

• Technology trends that shape tomorrow.
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By offering diverse, captivating stories, Business Insider empowers readers to stay ahead of the curve and discover the narratives that truly matter.

Broken motors and crumple zones

Stuyvesant High School Robotics Team Tackles Motor Packaging Issues

Clare, Mueller, and Yao form a dedicated robotics squad at Stuyvesant High School in New York City. While Clare is a junior, both Mueller and Yao are seniors, bringing a mix of experience and fresh perspective to the group.

Genesis of the Kiriboard Initiative

• During a routine shipment, students received Kraken X60 motors—each unit priced at roughly $200.
• Upon opening the package, they discovered brass pins that were cracked and rendered unusable.
• Initially, the trio believed the damage stemmed from transit mishandling.

Motivation for Improved Packaging

“We realized the packaging was inadequate,” said Mueller. Clare reflected on automotive engineering principles, particularly crumple zones, which absorb impact energy to safeguard passengers.

Key Takeaways

• The team identified a critical packaging flaw that endangered motor components.
• Clare’s analogy to crumple zones illustrates the importance of protective design in robotics and other engineering fields.
• Their experience underscores the necessity of robust packaging to prevent loss of high-value parts.

High School Robotics Lab Breakthrough

Team Members and Key Equipment

Clare, Yao, and Mueller were seen in their high school robotics lab during a recent demonstration.

Clare was holding a Kraken X60 motor while the team showcased their latest design.

Strategic Packaging Design

During the session, a note Clark Hodgin emphasized that strategic weak points in packaging can cause the package to warp and deforms, sparing the contents.

Collaborative Effort and Prototype Testing

• With help from the Earth Prize program and Citron, they built and tested their first Kiriboard prototypes.

The matrix

The Kiriboard Project

From Cardboard to College Creativity

Working with recycled cardboard scavenged from their school, three students turned humble material into a prototype that could withstand real-world shipping challenges.

Design Exploration

• After consulting teachers and reviewing tech studies, the team drafted nine distinct cardboard models.
• They trimmed the list to four final designs, each slated for physical testing.

Testing the Load

To evaluate each prototype’s durability, the teens performed a series of impact trials:

• A roll of tape, a compact stapler, a can of soda, and a metal water bottle were carefully dropped from varying heights.
• “Each impact gave us a clear picture of the forces involved,” Clare explained.
• Yao added, “Our goal is to find the maximum force a model can absorb before it snaps.”

Impact Results

The tests yielded encouraging outcomes:

• All four Kiriboard prototypes sustained minimal damage, measured by checking for dents in the cardboard.
• The biggest damage came from the metallic bottle, but it was still less severe than anticipated.

Future Directions

With promising results, the students plan to advance all four designs. They hope that each model will be suitable for a variety of shipping scenarios, ensuring that cargo can reach its destination safely.

Key Takeaway: By turning reclaimed cardboard into a reliable shipping solution, the trio demonstrates that resourceful design can withstand real-world pressures.

A Fresh Look at Kiriboard Packaging Innovation

The Trio Behind the Design Genius

• Zhi Han (Anthony) Yao – Visionary packaging strategist
• Flint Mueller – CNC automation pioneer
• James Clare – Robotics logistics champion

Trio’s Matrix Design – A Flexible Interface

The featured illustration reveals the core “matrix” area, the nexus that holds the Kiriboard snugly within a sturdy box. Yao explains that this segment must adapt fluidly to vary‑shaped cargo, acting as a flexible cradle that molds itself around the product during shipping.

Four Triangular “Legs” – The Steady Support

Securing the Kiriboard inside the container, the four triangular “legs” lock the hardware in place, ensuring that the package bears weight evenly as it travels.

Automation & Prototype Trials

After acquiring a CNC router to streamline cardboard cutting, the team intends to validate prototypes by shipping the boxes in real packaging scenarios. Yao emphasizes the current research focus: “We are refining the product until it is ready for market launch.”

Possible Pitch to Electronics Firm AndyMark

Once finished, the group might present the solution to AndyMark, the electronics company that previously shipped routers for the robots. J. Clare remarks the robotics team routinely orders from AndyMark without complications, reinforcing the potential partnership.

Team Morale & Last Effort

Flint Mueller acknowledges the near‑realization of the project, urging the crew to apply the final effort. James Clare, reacting to the faulty packaging that triggered the design, underscores the team’s resilience: “All from a broken package.”

Conclusion – A Collaborative Path Forward

Through smart design, automated cutting, and iterative testing, the trio aims to deliver a flexible, ship‑ready packaging solution that could soon be market‑ready, possibly in collaboration with AndyMark.