Low Carbon, High Impact: How Thermally Fused Laminate (TFL) Reduces Your Project’s Environmental Footprint

What is TFL?

Thermally Fused Laminate is a decorative surface created by bonding a printed paper layer to a composite wood core under high heat and pressure. The result is a pre-finished panel that mimics the look and feel of real wood or solid colors—without the resource-intensive drawbacks of traditional lumber products.

Why TFL Has a Lower Carbon Footprint

1. Made from Recovered Wood Fibers
   
   
   TFL cores are typically manufactured using 100% recycled or recovered wood fibers—such as sawmill residues, wood chips, and post-industrial waste. Some of the wood fiber also comes from parts of harvested trees not suitable for lumber, flooring, or siding—helping us utilize over 99% of the tree. This reduces the demand for virgin timber and diverts usable fiber from landfills, contributing to circular economy principles.
   
2. Fewer Emissions During Manufacturing
   Unlike solid wood or veneered products that require extensive sanding, staining, sealing, and finishing, TFL is produced in a single-step lamination process. Thermally fused laminate panels leave the factory with both faces already applied—no extra gluing steps are required. This streamlined manufacturing generates less waste, consumes less energy, and results in significantly lower greenhouse gas emissions per square foot.
   
3. North American Production
   At STEVENSWOOD®, our panels are made right here in North America using FSC and SFI managed forest resources. That means shorter transportation distances, lower associated emissions, and support for regional manufacturing. By avoiding transoceanic shipping, we further reduce the overall carbon footprint of your materials.
   
4. Wood: A Naturally Climate Positive Material
   Wood-based panels like TFL sequester more carbon than is released during harvest, production, and use. In fact, by weight, wood and wood fiber are 50% naturally captured carbon. For example, an 80-lb. sheet of particleboard sequesters about 40 lbs. of carbon—16 lbs. more than is released during production. The carbon footprint of 1 m³ of particleboard is a net negative 1,020 kg of CO₂. For comparison, aluminum has a footprint of 28,890 kg of CO₂—11 times heavier than the material itself.*
   
5. Longevity Reduces Replacement Cycles
   TFL is built to last. It resists scratches, moisture, impact, and fading—which means fewer replacements over time. Products that perform longer extend their lifecycle, reducing the frequency and environmental cost of replacement materials. The durability of STEVENSWOOD® TFL is comparable to HPL surfaces, ensuring it stands up in demanding environments.
   
6. Low VOC and Formaldehyde-Free Options
   STEVENSWOOD® offers panels with low-VOC emissions and no-added urea formaldehyde (NAUF) cores, making them safer for indoor air quality and healthier for occupants—without compromising on design.
   
   

A Smart Choice for Green Building

Whether you’re targeting LEED points, reducing Scope 3 emissions, or simply building more responsibly, TFL is a smart and sustainable choice. It combines visual appeal with measurable environmental advantages, helping you meet today’s design and performance goals while reducing your carbon impact.

_{*Figures provided by Material Intelligence, find out more about their Climate Positive Now campaign at Material Intelligence for Furniture and Interior Design}