Fiber Reinforced Solutions

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 is here to help you get the results you need, keeping your projects on time and on budget.

Advanced Manufacturing

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.

Sustainability

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

Widespread Application

ShapeShell™ serves markets such as Architectural Internal & External, Public Artwork, Civil Infrastructure, Moulds/Tools, and Formwork Markets collaborate with architects, builders, and installers

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.

Our Factory

Batam Factory Facility

Overview

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. ShapeShift Technologies is a vertically integrated company that has the ability to design and manufacture construction industry products using advanced materials, such as ShapeShell-RT (Reinforced Thermoset) and ShapeShell-RC (Reinforced Concrete), which are engineered to offer unique solutions. 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.

The Manufacturing Technique

Fibre Type Selection: The specific fibres used in ShapeShell™ are chosen based on the project’s structural and design requirements. Fibres may be selected for their strength, flexibility, or other unique properties that contribute to the material’s overall performance in its intended application.
Weave Pattern Customisation: The fibres are woven into specific patterns, which are determined based on how the final product needs to respond to physical stresses. Different weaving patterns can enhance tensile strength, flexibility, or rigidity, providing tailored performance characteristics for the ShapeShell™ material.
Custom Manufacturing Processes: The manufacturing process for ShapeShell™ is adapted for each project. Techniques may include specialised moulding, pressing, or curing processes that align with the desired shape and performance of the final product.
Resin System Formulation: The resin system is a critical component, acting as the binder for the fibres. The choice of resin influences the product’s environmental resistance, durability, and longevity. The resin system used in ShapeShell™ is selected to meet stringent international and Australian standards for fire retardancy and other critical properties.
Optimized Resin-to-Fibre Ratio: The ratio of resin to fibre is meticulously calculated to balance the material’s weight, strength, and flexibility. This optimisation is crucial for ensuring that ShapeShell™ delivers a high-performance, lightweight solution that can be safely and easily installed without heavy machinery.