Carving Creativity: How to “Jack-o-Lantern” Molded-Pulp Packaging for a Spooky, Sustainable DIY
Every Halloween, many of us are hunting for fun, eco-friendly craft ideas that don’t involve single-use plastics. If you have some spare molded-pulp packaging lying around (clamshells, inserts, stands) you’re in for a treat: you can repurpose it into charming jack-o’-lanterns. Molded pulp’s texture, thickness, and natural fiber makeup make it especially suited for carving — and your finished lanterns are fully recyclable or compostable. Here’s your step-by-step guide to a sustainable, arts-and-crafts DIY.
Why Molded Pulp Makes Great Pumpkin Material
- Natural & eco-friendly: Molded pulp is made from recycled cardboard and paper fibers, giving it a warm, earthy tone that’s perfect for fall and Halloween. Sustainable Packaging Industries+1
- Rigid but workable: Unlike thin, flimsy paper, molded pulp has enough structure to hold its shape, yet it’s soft enough to carve with simple tools.
- Repurposability: This isn’t just creative – it’s circular. After your jack-o’-lantern has done its duty, you can recycle or compost it along with other fiber-based materials. Sustainable Packaging Industries
No plastic waste: By turning packaging into décor, you’re reducing plastic usage and giving a second life to what might otherwise be discarded. This aligns with SPI’s commitment to sustainability. Sustainable Packaging Industries
What You’ll Need
| Item | Purpose |
| Molded-pulp piece (clamshell, tray, insert) | Your “canvas” – pick something with a smooth, curved surface if possible. |
| Cutting tool | A small craft knife, “X-Acto” blade, or lino-cutting tool works well. |
| Pencil or marker | To sketch the face before carving. |
| Cutting mat or protective surface | To protect your table or workspace. |
| Optional: LED tea light | For safely illuminating your pumpkin without heat damage. |
| Optional: Paint or markers | To add color or accent details. |
| Light sandpaper (optional) | To smooth any rough edges. |
Step-by-Step Guide to Carving Your Pulp Pumpkin
Create the Artwork
The process begins by laying out the artwork in Canva.com to determine the exact placement within the printable area of the clamshell. This step ensures the design aligns properly with the packaging size and shape.
Mock Up the Design
Before making the screens, it’s essential to mock up the design. Printing the artwork on paper and cutting it out allows for a quick test fit—helping visualize the placement and scale on the actual packaging.
Select the Ink
Next comes choosing the ink color. We use PERMAPRINT Premium, a 100% solvent-free, environmentally friendly water-based screen printing ink. Not only is it vibrant, but it’s also a sustainable choice.
Print the Clamshells
With the design and ink selected, the final step is printing directly onto the packaging. This is where the magic happens—transforming plain clamshells into branded pieces that are textured, eye-catching, and full of personality.
More Information
Packaging Materials
GK-002 Clamshells
Hanging Sleeves
Custom Print
Soap Dev
an ex california line cook who makes soap and other tioletery products that cleanse your hands, body, & face.
Website
www.soapdev.com
Social Media
@soap_dev/
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