Benefits of Fibre-Reinforced Thermoset for Complex Architecture
ShapeShell™ RT is a high-performance, fibre-reinforced thermoset material developed by ShapeShift Technologies for architectural applications that demand structural strength, design freedom, and durability. It is a next-generation fibre-reinforced polymer (FRP) substrate, composed of high-strength fibres (such as glass, carbon, aramid, or basalt) embedded in a thermoset resin matrix. The reinforcement is arranged in multi-axial fabric layers, optimised for high performance in multiple directions. At its core, ShapeShell™ RT is engineered to be lightweight yet structurally resilient—offering up to five times the strength of aluminium while remaining significantly lighter. Thickness can be tailored to project needs, ranging from 3 mm to 50 mm depending on the performance and monocoque requirements. Engineered for Complex Geometries One of ShapeShell™ RT’s standout advantages is its adaptability to intricate and fluid geometries. Thanks to advanced manufacturing methods, including vacuum infusion, it achieves a uniform resin distribution throughout the fibre layers. This makes it ideal for freeform, double-curved panels and monolithic shapes that are otherwise difficult or cost-prohibitive with conventional materials. ShapeShell™ RT has been employed in landmark projects such as the Barak Portrait Façade in Melbourne, where over 400 uniquely shaped double-curved panels were fabricated, each carrying structural loads via monocoque construction. The system’s geometry flexibility enabled seamless visual integration while meeting stringent structural demands. Performance Attributes From a technical perspective, ShapeShell™ RT offers outstanding mechanical properties: Flexural strength: up to 241 MPa Tensile strength: up to 269 MPa Compressive strength: up to 228 MPa Impact resistance: 643 J/m Water absorption: <0.1% Fire rating: Class A under ASTM E84 The material also withstands extreme weather conditions—passing accelerated UV, freeze-thaw, and salt spray tests—making it suitable for both interior and exterior applications. Integrated Installation System ShapeShell™ RT panels come with a proprietary attachment system designed for ease of on-site alignment and secure anchorage. The system accommodates building tolerances with ±20 mm adjustability and uses corrosion-resistant materials such as aluminium and stainless steel (Grade 316). In short, ShapeShell™ RT is not just a material but a comprehensive cladding and structural solution. It provides architects and engineers with an innovative medium to realise expressive forms, optimise weight, and maintain performance integrity across decades of use. Whether used in facades, sculptural installations, or large-scale infrastructure, it exemplifies the intersection of aesthetics, functionality, and buildability. 5× Strength of Aluminium – What That Means for Architecture ShapeShell™ RT’s defining characteristic is its exceptional strength-to-weight ratio, offering up to five times the strength of aluminium while remaining substantially lighter. This advantage opens up a new realm of possibilities in architectural design, particularly where structural performance, weight constraints, and aesthetic freedom must all be balanced. Translating Strength into Design Freedom In traditional construction, strength often comes with trade-offs—heavier materials, bulkier structural support, or geometric limitations. With ShapeShell™ RT, designers can push the boundaries of form without compromising safety or constructability. Its tensile strength reaches up to 269 MPa, and its flexural strength extends beyond 240 MPa, meaning it can withstand substantial loads and forces even in thinner, more sculptural profiles. This strength allows for: Longer spans and larger cantilevers without secondary steel framing Reduced panel thickness while maintaining structural integrity Slender and organic geometries that mimic natural forms or artistic intent Minimised substructure, reducing cost and installation complexity Weight Efficiency and Load Reduction Despite its strength, ShapeShell™ RT remains remarkably lightweight, with material density as low as 5 kg/m² in standard configurations. This weight efficiency is especially beneficial in high-rise or retrofit projects, where structural loads must be carefully managed. In the Queens Domain project in Melbourne, ShapeShell™ RT’s low weight enabled the design team to reduce the slab thickness across 20 storeys—freeing up enough height to add an additional level within planning constraints. Enhanced Seismic and Wind Performance Stronger and lighter materials also mean better response to lateral loads such as wind or seismic activity. ShapeShell™ RT panels offer greater ductility and resilience under such dynamic conditions compared to brittle or heavy alternatives. This has made the material a go-to solution for projects like the West Gate Tunnel in Melbourne, where over 28,000 m² of panels needed to perform under significant environmental stresses. Simplified Installation and Reduced Construction Risk The material’s strength also directly supports faster and safer installation. Fewer structural connections and lighter components reduce crane loads, lifting time, and overall labour on site. In projects like The Allen Pavilion in Houston, panels were designed for aesthetic and structural purposes, eliminating the need for steel cladding supports and reducing construction duration without compromising quality Application Examples – Sweeping Forms and Cantilevers One of the greatest architectural advantages of ShapeShell™ RT lies in its ability to realise sweeping forms and daring cantilevers—elements that traditionally require complex engineering and heavy support systems. This capacity is not theoretical; it is demonstrated across a wide range of completed projects where ShapeShell™ RT has transformed bold design intent into buildable, structurally sound reality. Freeform Geometry with Structural Integrity ShapeShell™ RT excels at translating freeform, organic, or double-curved geometries into tangible, high-performance building elements. Its monocoque construction technique—where the skin of each panel carries the structural load—means designers are not constrained by conventional framing. In the Barak Portrait Façade in Melbourne’s CBD, 411 unique panels were created, each forming part of a large-scale image. Despite their complexity, the panels were engineered with up to 2.5 m of vertical cantilever from slab edge, eliminating the need for secondary supports. Monumental Cantilevers – Case in Point In the Commonwealth Games Parklands Disk in Gold Coast, ShapeShell™ RT was used to fabricate a 25-metre-diameter public art piece, featuring a 15-metre cantilever with an integrated water blade and complete waterproofing. Built with just 34 large panels (some up to 10 metres long), the disk was structurally engineered to resist environmental forces while meeting exacting visual and functional requirements. Similarly, in the Spanda project at Elizabeth Quay in Perth, the tallest ring—29 metres high—was constructed from ShapeShell™ RT, taking advantage of its lightweight strength. The rings were lifted and installed as complete units, despite the extreme cantilevers involved. Advanced
