A 3D Z-axis fiber composite pallet, comprising a Z-axis reinforced sandwich panel including a bottom surface with a plurality of bolted-on and/or structurally bonded blocks that accommodate forks of a forklift there between, and a tough coating applied to surfaces of the 3D Z-axis fiber composite pallet.

A modular pallet formed from a plurality of frame members and a plurality of deck members. The deck members extend between the frame members to define an upper deck surface and optionally a lower deck surface of the pallet. A plurality of spaced-apart channels are formed in at least an upper surface of the frame members to receive the deck members. In some embodiments the pallet may be configured as a stringer pallet and in other embodiments the pallet may be configured as a block pallet. In some embodiments the frame members are unitary stringers. In other embodiments the frame members are modular structures each comprising a block pallet subassembly and a deck support panel. The number, size, orientation and spacing of the channels formed in the frame members and the corresponding arrangement of the deck members may vary in different embodiments of the pallet. Once assembled, the frame members and deck members may be integrally connected, such as by heat welding. In some embodiments the pallet is formed from readily recyclable plastic.

Wood scrap and binder components forming raw material (1) of a pallet block are prepared in accordance with predetermined mechanical properties of the pallet block to be produced with a mass equal to the predetermined mass of the finished pallet block. The prepared components are mixed and fed into a press mould (3) of a press die (2), pressed to size, and the binder is cross-linked applying heat externally by the aid of the side walls (11) of the press mould (3) and at the same time internally by applying heat to the central region of the pallet base material (1) via a central forming mandrel (14) conducting hot steam into the pressed the pallet block, thereby promoting the cross-linking of the pallet base material's binder in short time. The invention also relates to an apparatus implementing the method.