Pakenham Railway station achieves unprecedented sustainability and building precision through a decade-long collaboration between architectural firm Genton and design, engineering, and manufacturing company ShapeShift.

The groundbreaking digital fabrication technology applied to Pakenham Station uses thermoset, a digitally engineered synthetic that strengthens when heated, as a sustainable agent that saves on time and materials. Genton principal Jamie McCutcheon says its use stands in direct opposition to the commonly ‘dirty’ practices of the construction industry that contribute to pollution on a global scale. 

“Digital fabrication is fast becoming one of the most sustainable and innovative construction techniques,” McCutcheon says.  “By adopting this approach, we aim to reduce the environmental impact by minimising raw material usage and the need for numerous prototypes.” 

To make up for a lack of enhanced sustainability and efficiency in the construction industry over time, the collaboration of Genton and ShapeShift has opened the door to opportunity with their innovative approach to building and design that not only reduces the use of raw materials but allows architects to apply their creativity to civic projects using digital technologies.

Suburb’s rolling hills inspire station roof design

Pakenham Station’s high-tech roof, a wave-like canopy made from reinforced thermoset, showcases the power of digital manufacturing in the rail sector. This meticulously designed structure reflects Genton’s original vision with remarkable accuracy, thanks to computer-generated technology that ensured efficient manufacturing, saving both time and materials.

By leveraging the expertise of both Genton and ShapeShift, the application of 3D technology and digital manufacturing has refined the digital fabrication process, allowing for the delivery of this complex structure with cutting-edge technology.

“This is the first time the technology has been used in a live rail environment,” McCutcheon says. “What starts as a sketch on paper can be digitally reproduced with incredible accuracy,  ensuring a guaranteed design. The 3D fabrication process allows us to harness our creativity as architects, combining our ideas with computer programs that create sophisticated dynamic models.”

McCutcheon believes this technology will change the design and construction of rail infrastructure forever, promising greater architectural freedom, higher sustainability outcomes, improved onsite delivery and faster construction times. 

A collaboration of experience, architecture and design 

The partnership between Genton and ShapeShift points to significant progress towards a technologically advanced and environmentally mindful construction sector; one that aims to set higher standards for sustainability benchmarks and improve efficiency in project execution.

“Our collaboration with Genton on Pakenham’s roof is a testament to the innovation of digital fabrication and its ability to modernise the construction industry, ensuring product precision and quality,” says ShapeShift CEO Toby Whitfield.

McCutcheon adds: “Using ShapeShift’s advanced technology, we’ve been able to remove a lot of secondary steel from the project, delivering a sustainable solution and significant cost savings for the client.”

Standing as a stalwart piece of innovation, technology and sustainability, the new Pakenham Station will spearhead a new era of rail development through its application of digital fabrication technology, fostering a creative and environmentally-conscious perspective in architectural and construction methodologies.

Lead image provided by Genton.

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