Lightweight Strength: ShapeShell™ RT for Interior Projects

The Challenge of Building Better Interiors

In today’s architectural landscape, interiors are no longer an afterthought. They are the spaces where people spend most of their time — studying, working, socialising, or simply living. Architects and consultants are under pressure to create environments that are not only visually engaging but also safe, durable, and efficient to build.

Yet, many conventional interior materials come with trade-offs. Plasterboard may be light, but often lacks long-term durability. GFRC (glass fibre reinforced concrete) or precast solutions offer durability but are typically heavy, difficult to install, and limit design freedom. Even metal cladding, though strong, brings issues of corrosion, acoustics, and weight.

What if there were a material that could combine the lightness of plasterboard, the durability of concrete, and the design versatility of polymers? A material that also simplifies installation while offering a high-end aesthetic finish?

This is where ShapeShell™ RT — a fibre-reinforced thermoset system — is transforming how architects think about interior projects

Why ShapeShell™ RT is Different

ShapeShell™ RT is a next-generation fibre-reinforced thermoset material, engineered for architectural performance. Built from advanced fibres (glass, carbon, aramid, basalt, or steel) embedded in a polymer resin, RT delivers five times the strength of aluminium while remaining exceptionally lightweight.

At its core, RT combines aerospace-inspired manufacturing with architectural intent:

• Lightweight panels with a thickness as slim as 3–8 mm for single skins, yet capable of spanning large internal surfaces.

• Strength and safety built into the fibre-resin matrix, including Class A fire rating under ASTM standards.

• Versatility in form: curved panels, freeform surfaces, and intricate detailing are achievable through advanced CNC tooling and vacuum infusion techniques.

Unlike gypsum or concrete-based systems, ShapeShell™ RT does not absorb moisture, degrade over time, or require excessive maintenance. Its low water absorption (<0.1%) ensures that even in humid or high-traffic interiors, the panels retain their performance.

Designed for Interiors

While RT has proven itself in large-scale infrastructure — from bridge cladding on the West Gate Tunnel in Melbourne to façade systems in Houston — its benefits translate powerfully to interiors.

For example, at Deakin University Law School, ShapeShell™ RT panels were used across 9,816 sqm of internal cladding. The result was a space that combined acoustic comfort, fire safety, and bold architectural form, all delivered within a fast installation timeframe.

Inside, the material enables:

• Seamless finishes for lecture theatres, offices, and foyers.

• Durable surfaces that resist scratches, wear, and moisture.

• Custom geometries that reflect the architect’s design intent rather than the limitations of traditional boards or panels.

The Value of ShapeShell™ RT Indoors

1. Lightweight Advantage

The most obvious benefit of RT in interiors is its lightweight profile. With a panel weight of only 5–32 kg/m² depending on thickness, it reduces structural demands on walls, ceilings, and secondary frameworks.

For contractors, this translates to:

• Faster installation with less need for heavy lifting equipment.

• Lower labour costs due to simplified handling.

• Minimal disruption in retrofit projects, as panels can be fixed onto existing structures.

In projects like the Queens Domain apartments in Melbourne, RT balustrade panels were installed using only a 500 kg winch system — a process that saved significant time and cost. For interiors, this efficiency can make the difference between a drawn-out fitout and a seamless delivery.

2. Durability and Safety

Interior cladding must meet stringent fire safety, durability, and performance standards. ShapeShell™ RT achieves:

• Class A fire rating (ASTM E84) with low flame spread and smoke development.

• Resistance to corrosion, mould, and fungi, ensuring longevity in varied interior conditions.

• Impact resistance that far outperforms plasterboard or thin gypsum-based panels.

This makes RT ideal for high-traffic spaces such as universities, airports, cultural venues, and commercial interiors where panels must remain intact and visually appealing for decades.

3. Design Freedom

Architects increasingly seek materials that support freeform and expressive interiors. ShapeShell™ RT is designed for complex geometries. Using advanced 5-axis CNC tooling, it can be formed into sweeping curves, folded forms, or custom 3D panels without compromising structural integrity.

Finishing options further expand the creative palette:

• Gloss or matte coatings in full RAL colour spectrum.

• Cementitious finishes that harmonise with concrete or off-form elements.

• Metallic finishes emulating bronze, titanium, corten, or stainless steel.

• Primed-only surfaces ready for project-specific coatings.

This range ensures that RT is not only technically superior but also aesthetically adaptable to diverse interior schemes — from minimalist learning environments to premium cultural venues.

4. Sustainability

Beyond performance, RT contributes to sustainability goals. Compared to traditional materials, ShapeShell™ products achieve up to 400% lower CO₂ emissions by optimising raw materials and reducing weight across the project lifecycle.

The material’s long life span (50-year structural warranty, 25-year surface finish warranty) further reduces replacement cycles, aligning with green building objectives such as LEED and Green Star.

Case Examples

Deakin Law School, Melbourne

ShapeShell™ RT was used to clad internal spaces across five levels, supporting biophilic and sustainable design principles. The lightweight panels allowed rapid installation while creating smooth, curved interior lines that elevated the academic environment.

Sydney Opera House Concert Hall

In 2022, 192 sqm of RT sound deflectors were installed as part of the Opera House renovation. The surfboard-shaped panels optimised acoustics while maintaining architectural harmony, showcasing RT’s functional and aesthetic versatility for interior applications.

Wesley Place Lobby Pillar

We deliver the lobby pillar and plinth wall panels for the main lobby, a high-traffic zone requiring both durability and refined detailing. Using ShapeShell™-RC, a lightweight fibre-reinforced concrete system, the panels were fabricated as thin-walled elements (15–25 mm) that balance strength with reduced weight.

These examples illustrate how RT can shift from academic to cultural settings, proving its adaptability and reliability.

Bringing ShapeShell™ RT into Your Interior Projects

For architects and consultants, the interior material palette is a balancing act between weight, strength, safety, and design freedom. ShapeShell™ RT resolves this tension, providing a single solution that supports all four.

• It is lightweight yet strong, simplifying installation and reducing structural loads.

• It is durable and fire-rated, ensuring safe, long-term performance.

• It provides aesthetic versatility, from raw concrete tones to metallic sheens.

• It supports sustainable goals, with reduced embodied carbon and a long lifecycle.

If you are working on an interior project — whether a university, cultural venue, commercial space, or retrofit — ShapeShell™ RT offers an advanced option for cladding, lining, and design expression.

To explore its capabilities further:

• Request a ShapeShell™ RT sample for your material library.

• Access the technical data sheet for detailed performance specifications.

• Contact ShapeShift Technologies to discuss how RT can be integrated into your next project.

Lightweight strength isn’t a contradiction. With ShapeShell™ RT, it’s the new standard for interior architecture.