ShapeShell™ is a vertically integrated Design, Engineering and Manufacturing business that combines modern structural fibre-reinforced materials with advanced manufacturing methods to deliver specifically designed products for the Architectural/Construction Industry.
ShapeShell™ combines the latest aerospace-grade materials with precision manufacturing techniques and is renowned for its exceptional structural integrity, performance, durability, and affordability.
ShapeShell’s next-generation solutions outperform conventional materials across all key areas while meeting global testing certifications, ISO 9001 design and manufacturing standards, and offering up to a 50-year warranty.
We are committed to providing high-quality materials that stand up to the toughest conditions while maintaining a great look. Whether you need a standard profile or a custom design, our process is straightforward, ensuring quick turnarounds and minimal hassle from concept to installation.
From choosing the right materials to the final fit-out, we are here to support you every step of the way, with hands-on guidance and practical expertise. ShapeShell™ products are crafted with the latest technology and high-grade materials, giving you a reliable, high-performing solution that’s easy to work with on-site. ShapeShell™ by ShapeShift Technologies is here to help you get the results you need, keeping your projects on time and on budget.
Next Generation : Glass Reinforced Plaster
What is ShapeShell™-RG?
ShapeShell™-RG is a lightweight, strong, and versatile construction material composed of high-strength gypsum and glass fiber reinforcement. It’s known for its durability, flexibility, and aesthetic versatility, making it ideal for architectural applications.
Product Composition
Composed of high-strength gypsum combined with glass fibers to create a lightweight, durable, and versatile material. The gypsum forms the primary base, known for its natural fire resistance, smooth finish, and eco-friendliness, while the embedded glass fibers provide structural reinforcement, improving tensile strength and impact resistance. This combination allows ShapeShell™-RG to be molded into complex shapes and intricate designs without compromising durability. The glass fibers also reduce brittleness and add flexibility, enabling ShapeShell™-RG to be used in a range of architectural applications, particularly for decorative elements like cornices, columns, and panels, where both strength and aesthetic flexibility are essential.
Production Method
The production of ShapeShell™-RG involves mixing high-quality gypsum with glass fibers to create a reinforced composite material. The process begins with preparing a slurry by combining gypsum powder with water and adding chopped glass fibers. This mixture is then poured into molds, which are shaped to form the desired architectural element, whether it be a decorative panel, column, or other intricate design. This can have additional sanding, painting, or coating processes to enhance aesthetics and surface durability. This production method results in lightweight, strong components that are ready for installation in a variety of indoor applications, particularly where fire resistance and design flexibility are essential.
Key Advantages
Composition:
GRG (Glass Reinforced Gypsum) is a gypsum plaster reinforced with glass fibres, commonly used for lightweight interior panels and decorative elements. ShapeShell™ RG advances this concept by combining gypsum with modern fibres and exclusive polymers, resulting in a lighter, stronger, and non-combustible material.
Applications:
GRG is suited to simple mouldings, ceilings, and low-traffic interiors. ShapeShell™ RG extends these applications to complex geometries such as domes, vaulted ceilings, column covers, and feature wall panels, while providing greater durability and impact resistance
Composition
GRG often incorporates cellulose or paper layers that can be vulnerable to moisture. ShapeShell™ RG uses a gypsum–fibre–polymer matrix that eliminates cellulose, ensuring moisture, mould, and fire resistance.
ShapeShell™-RG refines this approach by combining gypsum with modern fibres and polymers, eliminating cellulose content and enhancing structural performance. Manufactured to ASTM standards, it delivers consistent quality, superior flexural and compressive strength, greater impact resistance, and full non-combustibility — making it a more versatile and resilient choice for complex architectural interiors.
Manufacturing Process
GRG is typically produced by hand-casting gypsum slurry into moulds with glass fibres. This labour-intensive method often results in variable thickness, surface quality, and strength, requiring additional finishing and careful handling during installation.
ShapeShell™-RG is manufactured under ASTM C1355 and C1381 standards using precision moulding and controlled curing. This process ensures consistent thickness, higher structural reliability, and surfaces ready for primer and paint, reducing on-site finishing and improving overall quality.
Performance Characteristics
GRG performs adequately for decorative and non-structural applications but is relatively fragile, with limited resistance to impact and moisture. It is prone to chipping, cracking, and deterioration in humid conditions, restricting its use to controlled interior environments.
ShapeShell™-RG offers superior performance with flexural strength of 24 MPa and compressive strength of 49 MPa, combined with excellent impact resistance and dimensional stability. It is 100% non-combustible, moisture-resistant, and lightweight, making it reliable for complex interior geometries that demand both durability and safety.
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Feature
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GRG
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ShapeShell™-RG
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Material Composition
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Gypsum with glass fibres, may include cellulose
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Gypsum with modern fibres & polymers, no cellulose
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Strength-to-Weight
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Moderate
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Higher (24 MPa flexural, 49 MPa compressive)
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Flexibility in Shapes
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Basic decorative forms
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Complex geometries (domes, vaults, columns)
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Durability
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Prone to cracking & moisture damage
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Impact-resistant, moisture-proof, non-combustible
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Surface Finish
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Needs extra prep/finishing
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Ready for primer/paint, custom finishes
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Manufacturing
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Hand-cast, variable quality
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Precision moulding to ASTM standards
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Applications
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Ceilings, mouldings, light panels
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Feature walls, domes, vaulted ceilings
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While GRG remains a common interior solution, ShapeShell™-RG represents a modern upgrade — lighter, stronger, sustainable, and designed for complex geometries. For architects and consultants seeking reliable and high-performance internal finishes, ShapeShell™-RG is the superior choice.
ShapeShell™ uses digital manufacturing methods to remove cost and allow investment into high-end materials, and their processes and scale allow access to this technology and quality at a competitive price.
ShapeShell™ represents the leading edge in a consolidated response to sustainability, where 3D Design & Engineering, Advanced Materials, and Digital Manufacturing methods result in Efficiency and sustainability
ShapeShell™ serves markets such as Architectural Internal & External, Public Artwork, Civil Infrastructure, Moulds/Tools, and Formwork Markets collaborate with architects, builders, and installers
The advanced manufacturing facility of ShapeShell™ is in Batam, Indonesia, near Singapore’s major shipping hub. The facility has an area of 20,000 m2 with 8,000 m2 under roof. The facility has an average of 50,000 m2 of material throughput per year, or 4,200 m2/month.
ShapeShell™ emerges from the synergy between architects, builders, and installers, providing bespoke solutions that push the boundaries of modern construction. ShapeShell™ offers unique solutions for the construction industry, using advanced materials and collaborating with architects, builders, and installers.
The methodology used by ShapeShift Technologies is significant and environmentally and commercially beneficial because it allows for the use of advanced materials, efficient manufacturing processes, and collaboration with architects, builders, and installers.
The manufacturing process used by ShapeShift Technologies is performed under vacuum, which results in consistent mechanical properties for each part. Additionally, the company has multiple easily accessible fabrication facilities in Asia, is scalable, and works under a detailed quality management system accredited to ISO 9001. All these factors contribute to the environmental and commercial benefits of the methodology used by ShapeShift Technologies.
