Plywood is popular for DIY projects, but is it the only ideal material for furniture, shelving, and outdoor construction? The answer is no. Plywood alternatives can be more cost-effective and resistant to moisture and corrosion. They include particleboard, solid wood, fiberboard, EKO ply, and more.
Particleboard
Particleboard, aka chipboard, is made from gluing small wood particles like sawdust and wood chips with resin under high pressure. It’s a cheaper alternative to plywood.
The most notable feature of particleboard is that it’s lightweight and easy to work with. You can easily cut, trim, or shape it. It is also ideal for lightweight furniture like drawer bottoms and temporary structures where aesthetics is not the priority.
While it’s stable, uniform, and strong enough to handle basic furniture needs, it’s not as durable as plywood. It tends to sag under heavy loads, and when it absorbs water it can swell, warp, and degrade easily.
Some particleboard types contain formaldehyde, but there are several formaldehyde-free options available on the market.
Pros:
- Cost-effective
- Smooth surface
Cons:
- Low strength and durability
- Not moisture resistant
Fiberboard
Fiberboard is made from tiny wood fibers held together with an adhesive. There are two main types:
Medium Density Fiberboard (MDF)
MDF is made from loose wood fibers. This engineered wood product is made by gluing those loose wood fibers with wax and resin and then compressing them to make sturdy boards. This makes MDF denser than plywood and stable enough to handle most projects.
If you’ve read our guide on what plywood is, then you know that it has naturally crisscrossing wood grains, knots, and rough surfaces. Medium-density fiberboard, on the other hand, has no wood grain patterns and is incredibly smooth. This makes it easy to paint, veneer, laminate, or finish.
This affordable material is highly resistant to warping and shrinking. However, MDF is heavier than plywood and not as strong. To make things worse, it has low moisture resistance.
Pros:
- Smooth surface
- Affordable
- Easy to work with
Cons:
- Not moisture resistant
- Can be quite heavy
High-Density Fiberboard (HDF)
As the name implies, HDF is stronger, denser, and harder than other fiberboards. This is because its wood fibers are compressed with more force, giving it a harder surface.
While its ease of use makes it ideal for construction and flooring, the most common use case for HDF is furniture-making. This is thanks to it not having any wood grains.
High-density fiberboard is popular because of its high strength-to-weight ratio. Despite being lightweight, it is strong enough for projects where durability is a priority. It’s even more moisture-resistant than most MDF products.
Sadly, HDF isn’t as strong as plywood. It requires special touches like painting or staining for outdoor use. Otherwise, it’ll quickly give in when exposed to the elements.
Pros:
- Strong and durable
- Affordable, even though it’s more expensive than plywood
Cons:
- Scratches and chips more easily than plywood
- More expensive than plywood
Oriented Strand Board (OSB)
Oriented strand board (OSB) is made from compressing and bonding wood strands that are oriented in crisscrossing patterns. This process enhances the durability of the board.
Oriented strand board is not as strong or durable as plywood, but it is sturdy and cheap enough to be a worthwhile alternative. That’s why it’s a popular choice for sheathing walls, roofs, floors, and subfloors.
OSB is environmentally friendly in more ways than one. First off, since it’s sourced from fast-growing trees, it’s sustainable. Furthermore, its production process does not typically involve dangerous chemicals like formaldehyde.
Oriented strand board is, however, heavier than most materials and has low water resistance. If you plan to use it in damp areas or outdoors, you’ll need to properly seal it.
Pros:
- Very strong and durable, almost on par with plywood
- Cheaper than plywood
- Eco-friendly option
Cons:
- Heavier than other alternatives
- Not fully moisture-proof
Polyurethane Board
Polyurethane boards are not sourced from trees. Rather, they’re made from plastic. This composition provides great thermal insulation, which is good for roofs, walls, and floors.
In addition to being cheaper, polyurethane boards are also waterproof alternatives to plywood. Since they’re made from plastic, they won’t warp or take water damage. This makes them suitable for outdoor projects or areas prone to dampness.
Polyurethane is lightweight, easy to work with, and versatile enough to be used by a single person for several applications. To make it stronger and last even longer, the material can be reinforced with fiberglass. These types are more pricey, though.
As a synthetic material, polyurethane board lacks the natural appeal that the wood grain surface of plywood offers. But, you can work around this by using artificial finishes that resemble plywood or other materials.
Pros:
- Moisture-resistant reducing the risk of rotting
- Lightweight while still strong enough to handle most indoor and outdoor applications
- Affordable and cost-effective
Cons:
- Not as strong as plywood
- May have a rough surface
EKO Ply
If you’re an environmentally conscious person like me, you should consider EKO ply. It is made from fully recycled materials and is stronger and more durable than regular plywood. However, it’s not as strong as some plywood types like marine or exterior.
EKO ply is chemical, rot, and corrosion-resistant. It’s also affordable and requires little to no maintenance. To add, this weatherproof material is easy to cut and holds screws well.
EKO ply’s recycled origin can make it less visually appealing than traditional plywood. It also makes it difficult to identify the exact composition of the wood. Moreover, due to variations in the manufacturing process, you may end up with pieces that are not as durable as expected.
Pros:
- Eco-friendly option, usually made from 100% recycled materials
- Resistant to natural rot, harsh weather, corrosion, and more
- High durability and strength
- Requires minimal maintenance
Cons:
- Usually more expensive than plywood
- Does not have the appearance of real wood
Solid Wood
Solid wood is sourced directly from trees and does not involve any special processing, save cutting and finishing.
This plywood alternative has unique wood grain patterns and colors that make it easy to find pieces to suit your aesthetics. That’s why carpenters and woodworkers often use it for virtually every wooden application, from shelving to furniture making and cabinetry.
Solid wood is more expensive than other plywood alternatives. But since it comes in varying qualities and types, you should be able to find an option that fits your budget.
Solid wood has a tenacious life force. If properly maintained, it can last for generations. However, it requires more maintenance compared to engineered materials.
Pros:
- Enhanced strength, durability, and longevity
- Great aesthetic appeal
- Available in a wide range of finishes and designs
Cons:
- More expensive compared to other options on this list
- Can be quite heavy, which may be an issue for solo DIY projects.
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What to Read Next:
- How to Buy Plywood as Cheap as Possible
- Advantages and Disadvantages of Plywood for DIY Projects
- What is Plywood Used For?
Main Photo Credit: MDF Sheets Torkhov / Adobe Stock Free / License
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