Abstract: A pallet is constructed of a molded fibrous panel material comprising a sheet portion defining opposite planar surfaces, and a grid of intersecting ribs projecting from one of the planar surfaces of the sheet portion, the sheet portion and ribs being integrally molded from fibrous material. The pallet comprises a horizontal portion of the molded fibrous panel material forming an upper support surface of the pallet, and at least two spaced runners joined to the horizontal portion for engaging the ground to space the horizontal portion above the ground. Each runner comprises at least two vertical portions of the molded fibrous panel material arranged in parallel relation and bonded to one another. In one embodiment, a single panel member is folded along a series of parallel fold lines extending across a width of the member, so as to form the runners and the horizontal portion from the single member.

Abstract: A fibrous panel is molded in two or more progressively formed mold members each comprising a porous support plate to which a plurality of rigid mold pieces are affixed. The mold pieces are truncated 3D tapered structures, and are arranged on the support plate in a regular array so that an intersecting grid or lattice of channels is defined between them. A fiber stock is poured into a first mold member and the stock is compressed and dewatered to form a panel. The panel is removed from the first mold member and placed into a second mold member having narrower and shallower channels whose side walls are more upright than those of the first mold member. The panel is further compressed and dewatered in the second mold member, and is densified in both the vertical and lateral directions by virtue of the progressive formation of the mold members.