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 : 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.
Reinforced Materials
Fiber Reinforced Polymer (FRP) is a material composed of fiber reinforcements and a polymer resin that bonds the fibres. 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
Composition:
FRP is composed of a polymer matrix, which can be thermosetting (like epoxy or vinyl ester) or thermoset, reinforced with fibres such as glass, carbon, aramid, or basalt. The fibres provide strength and stiffness to the composite, while the polymer matrix offers adhesion and protection to the fibres.
Applications:
Common applications of FRP:
Composition
FRP is a broad category that includes various types of fibre-reinforced composites made from a polymer matrix (such as epoxy or polyester) and reinforced fibres (like glass, carbon, or aramid). The specific composition can vary widely depending on the intended use.
ShapeShell™-RT is a proprietary composite system that combines reinforced thermoset polymers (RT) with advanced fibre reinforcements. It uses high-performance glass or carbon fibres embedded in a resin matrix, designed for architectural and structural applications.
Manufacturing Process
FRP can be manufactured using various methods, including hand lay-up, spray-up, and pultrusion. The choice of method affects the final material’s properties and application.
ShapeShell™-RT employs advanced vacuum infusion techniques for its production. This process involves saturating the fibres with resin in a vacuum-sealed environment, ensuring uniform consistency and enhanced performance through optimized resin flow.
Performance Characteristics
FRP generally offers high strength-to-weight ratios, corrosion resistance, and impact resistance; however, its properties can vary significantly based on the type of fibres and resins used.
ShapeShell™-RT is engineered for superior performance with ballistic capability. Has specific advantages in enhanced durability against environmental factors and chemicals. Its design allows for greater precision in applications where structural integrity and aesthetic appeal are critical.
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Feature
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FRP
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ShapeShell™-RT
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Material Composition
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Polymer matrix with glass, carbon, or aramid fibers
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Advanced thermoset polymers with custom reinforcement
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Strength-to-Weight
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High
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Higher (optimized for architectural use)
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Flexibility in Shapes
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Moderate
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Exceptional (suitable for free-form and intricate designs)
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Durability
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Corrosion-resistant but can be brittle
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Superior durability with high impact resistance
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Surface Finish
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Requires additional finishing
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Built-in aesthetic finishes available
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Manufacturing
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Pultrusion, lay-up, or winding methods
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Robotic and CNC precision for complex shapes
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Applications
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Reinforcement, lightweight panels, marine, aerospace
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Free-form architectural panels, advanced facade systems
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In summary, while both FRP and ShapeShell™-RT ideal for building structural reinforcement, lightweight panels, and components in corrosive environments, ShapeShell™-RT is tailored for architectural and creative projects, where free-form shapes, durability, integrated aesthetics, and advanced performance are prioritized. It represents a premium solution for innovative designs that combine form and function.
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.
