Fiber Reinforced Solutions

ShapeShift’s Fiber Reinforced Solutions, known as ShapeShell™, combine the latest aerospace-grade materials with precision manufacturing techniques and are renowned for their 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 is here to help you get the results you need, keeping your projects on time and on budget.

ShapeShell™-RT (Reinforced Thermoset)

Next Generation : GFRP, GRP, FRP, Fiberglass, Carbon Fiber, Kevlar.

What is ShapeShell™-RT?

ShapeShell RT™, a type of Fibre Reinforced Polymer (FRP), is engineered for strength, precision, and versatility. Constructed from E-glass reinforcement fabrics embedded in a polyester resin matrix, ShapeShell RT™ panels are manufactured using advanced vacuum infusion techniques. To optimise resin flow during the infusion process, a flow medium is incorporated within specific laminates, ensuring uniform consistency and enhanced performance.

Composite

Fiber Reinforced Polymer (FRP) composites are materials composed of fiber reinforcements and a polymer resin that bonds the fibers. Such composites can also include core materials, fillers, and other additives to provide unique performance attributes and use layers of chopped standard glass mats. It is a versatile and durable material that is resistant to corrosion, weathering, and chemicals. FRP is made by combining two or more materials to form a composite with superior properties to the individual components.

Fabrication Processes

ShapeShell™-RT is fabricated by infusion/RTM process. The infusion process involves saturating the fibres with the matrix material. In infusion process using vacuum bagging where the fibres and matrix material are placed in a vacuum-sealed bag, and the pressure differential forces the matrix material into the fibres.

Key Advantages

Advanced fibres in thermoset resin.
5 times stronger than Aluminum
Modern fibres in a thermoset resin.
130% lighter than GFRC.
Latest non-woven multi-axial fabrics for efficient load transfer.

ShapeShell™-RC (Reinforced Concrete)

Next Generation : GFRC, GRC, Glass Reinforced Concrete

What is ShapeShell™-RC?

ShapeShell™-RC in the next reinforced concrete, specifically designed for heavy-duty architectural applications, where fire safety and durability are critical. This substrate is classified as non-combustible under the AS 1530.1 standard, making it highly suitable for projects that demand stringent fire resistance. In addition to its safety features, ShapeShell™-RC offers a range of protective coatings, including advanced fluoropolymer and gel coat finishes, which enhance both durability and aesthetic appeal.

Product Composition

ShapeShell™-RC essentially consists of the cement or calcium silicate formed by a chemical reaction of siliceous and calcareous material, reinforced by fibres. Those are:

Portland white cement

Reinforcing fibres

Fine aggregate

Mineral pigment and paint

Functional additive

Selected material filler proving extra smooth surface

Production Method

GRC or GFRG is batched and blended in accordance with industry standards using the specified mix design. Its mixture is sprayed and laid into moulds designed to match the shape and dimensions shown on the approved shop drawings. Where the thickness of the GRC 15-25 mm.

Product Appearance

GRC or GFRG is a through coloured fibre cement panel with no coating. The product surface of the sheet is characterised by a textured surface. The board receives a hydrophobation which prevent moisture ingress into the core of the panel.

Key Advantages

Advanced fibres in a cementitious matrix.
50% stiffer than standard GFRC
Modern fibres in a geopolymer matrix.
100% lighter than precast concrete panels.
Commingled nano raw-material additives and fibres.

ShapeShell™-RG (Reinforced Gypsum)

Next Generation : Glass Reinforced Plaster

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.

Gypsum Plaster: Gypsum is the primary material, known for its fire resistance, smooth finish, and versatility in molding.
Glass Fibers: These fibers add tensile strength, allowing the plaster to hold its form better and resist impact and cracking.

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.

Advanced fibres in geopolymer matrix.
Flexural Strength equivalent to GFRC
Modern fibres in a gypsum matrix.
30% lighter than GFRC.
Commingled nano raw-material additives and fibres.

Website design by EDynam