Location: Railway Ave & Henry Rd, Pakenham VIC 3810, Australia
Scope: Complex, curved geometry of the roof canopy, providing both aesthetic and sustainability benefits.
Architect: Genton
Completion Year: 2024
Developer: Level Crossing Removal Project (LXRP)
Installing Contractor: FacadeX
Main Construction Partners: John Holland, KBR, and Metro Trains Melbourne (MTM) – Key contributors under the North Western Program Alliance
ShapeShift Product: ShapeShell™-RT canopy panels
Located in Melbourne’s South-East, the new Pakenham Train Station is a premium commuter and regional railway station on the Pakenham line, designed to support the busy pedestrian and shopping precinct and create safer, more direct links between public transport, additional parking and the town centre.
The design was inspired by the regional landscape, particularly Pakenham’s rolling hills and bronze sunsets, with the roof canopy’s profile mirroring the undulating terrain and warm hues of the region. The station incorporates 14 skylights within the roof canopy, allowing natural light to permeate the interior, reducing reliance on artificial lighting and enhancing the ambiance. The station was conceived to act as both a functional transport hub and a modern architectural landmark, improving community access and functionality with integrated public spaces, solar panels, and rainwater harvesting systems that support the station’s sustainability goals.
Officially opening in June 2024, the spacious, light-filled station features a new courtyard with lush green landscaping and seating areas, adding a touch of nature to the structural design. Other additions include a bus interchange, 450 car spaces, secure bike parking, walking and cycling paths, and two dedicated pick-up and drop-off zones—making journeys more reliable and efficient for thousands of travellers every weekday.
The project involved collaboration between key companies, including John Holland, KBR, and Metro Trains Melbourne (MTM), as part of the North Western Program Alliance. This alliance was tasked with removing three level crossings and constructing the new Pakenham and East Pakenham stations, significantly enhancing the rail corridor. This project, a collaboration between architectural firm Genton and ShapeShift Technologies, introduced advanced digital fabrication techniques, notably the use of ShapeShell™ RT, to deliver a sustainable and accurate construction.
ShapeShift’s involvement was pivotal in the design and construction of Pakenham Station’s distinctive roof canopy. Utilising ShapeShell™ RT, a fibre-composite material typically employed in aerospace and nautical industries, the team achieved a roof profile inspired by Pakenham’s rolling hills and bronze sunsets. This material choice allowed for a reduction in steel usage and energy consumption during manufacturing and transportation. The integration of skylights within the roof canopy not only elevated the station’s aesthetic appeal but also contributed to sustainability by minimising the need for artificial lighting during daylight hours.
The canopy was also created using 3D printing technology, marking it as one of the first of its kind in Australia. This innovative process that created the unique roof profile inspired by Pakenham’s rolling hills and bronze sunsets, integrating advanced manufacturing processes with architectural vision. The team employed large-format CNC (Computer Numeric Control) machines to cut master patterns directly from 3D digital files, ensuring precision and efficiency. These CNC machines are among the largest in the southern hemisphere, underscoring the project’s scale and ambition.
The use of 3D printing technology also contributed to sustainability by reducing raw material use and minimising waste. The project also features additional green initiatives, such as solar panels and rainwater harvesting systems, which align with broader sustainability goals and demonstrate a commitment to responsible resource use, further enhancing the project’s overall environmental footprint. The process minimised raw material usage and reduced the need for multiple prototypes, aligning with the project’s environmental objectives. Additionally, the precision of digital fabrication facilitated unitisation, simplifying installation and enhancing overall efficiency.
A key feature of the modern-designed station and our contribution to the project is the iconic roof canopy, which was inspired by the signature bronzed sunsets of Australia and the rolling hills landscape of Pakenham with its curved structure.
Utilising our ShapeShell™-RT (the next generation of FRP) material, we provided a low maintenance, low environmental impact solution, whilst achieving the desired custom colour and finish – all critical elements to the overall success of the project.
The Pakenham Station redevelopment exemplifies the successful integration of advanced digital fabrication techniques in public infrastructure projects. ShapeShift Technologies’ application of ShapeShell™ RT and digital manufacturing processes, in collaboration with Genton, delivered a sustainable, efficient, and architecturally distinctive station that serves as a model for future infrastructure projects.
ShapeShift provides innovative, sustainable, and high-quality canopy and roofing solutions for modern architectural projects. If you’re ready to bring your vision to life with ShapeShell’s advanced FRP materials, contact us today!
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