Case Study: Custom Cuts for FormaShape

Project Brief:

FormaShape, a 3D architectural design solution firm and subsidiary of White Water Composites, was presented with a challenge from a client. They were tasked to build a structure that could endure harsh weather conditions. After exploring multiple options, FormaShape found RhinoKore’s honeycomb core structural panels to be their solution. RhinoKore worked closely together with them to ensure the final product exceeded expectations.


Client: FormaShape

Established in 1981, FormaShape is one of North America’s largest manufacturers of composite fibreglass in complex shapes and designs for the architectural and waterpark industries. They provide clients with professional engineering and manufacturing services to develop premium-quality products.


The Problem:

In the summer of 2017, FormaShape needed to create large structural panels that could handle extreme weather conditions. The final product needed to be able to endure hot summer temperatures, freezing winters, and the additional weight of snowfall. To keep everything produced on schedule and to the proper specifications, FormaShape needed an exceptional core material. They experimented with a variety of cores but they had difficulty finding a core that could meet their rigorous requirements of durability, weight, and strength. Then they met RhinoKore Composite Solutions.


The Solution:

The timing couldn’t have been more perfect as Formashape was just beginning to plan production. With exceptional durability, strength, and customization, RhinoKore’s honeycomb core panels fit seamlessly into FormaShape’s manufacturing stream. After testing and discussion, FormaShape decided to use RhinoKore’s P100 paper core due to its strength. Using phenolic treated kraft paper, the foam-injected core offered significant stiffness.



FormaShape used RhinoKore’s P100 foam-injected panels for their architectural project

FormaShape used RhinoKore’s P100 foam-injected panels for their architectural project


The Results:

While the core itself was ideal for application in the project, FormaShape also credits success to RhinoKore’s extensive product knowledge, customer support, and solution-oriented collaboration. Due to the unwieldy nature of the large panels, RhinoKore custom cut their core panels to assist FormaShape in streamlining production as well as reducing labor costs. FormaShape’s crew found the foam-injected cores to be easy to work with and were able to assemble perfectly consistent finished products. When there were hiccups in production, RhinoKore’s customer support was timely, informative, and effective. They were able to successfully produce the 14 ft. wide panels, and met the strict lamination and weight requirements.

Through this collaboration, RhinoKore exceeded FormaShape’s expectations. In addition, RhinoKore’s high level of service and attention to detail made them a stand-out choice against their competitors. Both FormaShape and RhinoKore were pleased with the end results and look forward to their next opportunity for collaboration.


Client Testimonial:

“Through a collaborative relationship with RhinoKore we were able to meet our customer’s expectations. Their P100 product and precise, custom cutting services has proven to be extremely easy for us to work with and perfectly suited this particular application.”

- Craig Pay, Vice-President and General Manager of Formashape


Do you have a project that needs custom cuts and foam-injected core panels? Check out our honeycomb panels and custom options. Our knowledgeable staff can work together with you to find a solution.



Custom cut panels from RhinoKore fit perfectly to specifications

Custom cut panels from RhinoKore fit perfectly to specifications

Honeycomb core panels lent significant stiffness, meeting strength requirements

Honeycomb core panels lent significant stiffness, meeting strength requirements