PaperShell

PaperShell presents a new generation of structural materials based entirely on biogenic inputs. By combining kraft paper with a natural binder derived from agricultural residues, the company has developed a high-performance composite that replaces conventional materials in demanding applications.

For The New State of Materials, PaperShell showcases its interpretation of the corrugated (sinus) profile – one of the most widely used geometries in construction and industry. Historically produced from steel, aluminium, or fibre-reinforced plastics, this geometry has defined efficient building systems for over two centuries, enabling lightweight, strong and cost-efficient construction – from rail infrastructure to global manufacturing. However, its legacy is deeply rooted in fossil-based and carbon intensive materials.

By replacing conventional materials such as aluminium, GFRP or steel sheets, PaperShell enables significant reductions in greenhouse gas emissions, while maintaining compatibility with existing production and installation methods.

PaperShell’s approach preserves the industrial logic of corrugation while fundamentally changing the material basis. Through a highly automated press-moulding process, the material forms rigid, double-curved and corrugated structures with high strength-to-weight performance. The resulting composite is strong, lightweight, and compatible with scalable production methods. At end-of-life, the material can be processed through controlled thermal or biological pathways, supporting circular material flows.