Shape on the Roll - 50th Anniversary Edition

TECHNOLOGY / PEOPLE / BUSINESS / PRODUCTS / MANUFACTURING Ja nua r y 2025 · I ssue 90

SHAPE ON THE ROLL 6

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FOUNDING 50

FUTURE 50

ANNIVERSARY CELEBRATIONS

Honoring the vision, determination, and legacy of Shape’s founders that transformed a small Michigan company into an industry leader.

Exploring the technologies, strategies, and bold initiatives that will drive Shape’s growth and impact for the next 50 years.

Celebrating five decades of Shape through global festivals and community events all over the world.

IT’S

IT

is

50 YEARS OF SHAPING AN INDUSTRY

SHAPE ON THE ROLL / ALSO IN THIS ISSUE: GLOBAL SERVICE PROJECTS · NEW TECH INNOVATIONS · EXPLORING SHAPE’S SUSTAINABILITY JOURNEY · EXCITING GROWTH IN OUR GLOBAL MARKETS

SHAPE ON THE ROLL

CEO LETTER

CONTENT

DEAR SHAPE FAMILY,

“

As we stand on the threshold of our 50th anniversary, I am reminded of how far we’ve come since the spark of innovation first ignited in 1974.

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FOUNDING 50

FUTURE 50

2024 marks the 50th Anniversary of Shape Corp.

Discover the story and milestones which shaped our solid foundation.

Get excited about the next 50 years. The future of Shape is bright thanks to exciting technology and smart, sustainable business.

FEATURES

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50TH ANNIVERSARY Celebrating the milestone by looking back and forward

FOUNDERS TRIBUTE Remembering the founders and figures that started it all

DECADES OF GROWTH Shape’s expansion and key milestones, 1974-2024

GLOBAL GROWTH Highlights from Shape facility expansions around the world

Shape celebrates the people and technology that make the company great.

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BACK

TECHNOLOGY CTO, Ed Pleet: Shape tech now and in the future

INNOVATION Product and process innovation: new process highlights

From our humble beginnings in a small office to becoming a global leader in advanced manufacturing, Shape Corp.’s journey has been nothing short of extraordinary.

Over the “Founding 50” years, our commitment to innovation has not only transformed our industry but has also shaped the lives of countless individuals – from the communities we serve to the partners and families that have grown with us. Our story is one of resilience, passion, and an unyielding drive to turn the improbable into the incredible.

Together, we’ve pushed boundaries, embraced change, and redefined standards. Our achievements are thanks to the dedication and expertise of our people— those who tirelessly contribute to our mission of shaping technology, shaping communities, and shaping a better future.

MARK WHITE SHAPE CORP. PRESIDENT & CEO We’ve accomplished so much, and the best is yet to come!

As we look forward to the “Future 50,” we remain committed to the values that have guided us: sustainability, diversity, excellence, and community impact. These principles are not just goals but the foundation upon which our future will be built.

I invite you to join us in celebrating this milestone as we honor our history and embrace the possibilities that lie ahead. Our journey is far from over, and together, we will continue to shape the future – with the same vision and passion that has defined us for the last fifty years.

25th Anniversary, 1999

40th Anniversary, 2014

Thank you for being a part of this remarkable journey. Here’s to the next 50 years of shaping an industry, shaping lives, and shaping the future.

Sincerely, Mark White President & CEO, Shape Corp.

50th Anniversary, 2024

GREENER TOMORROW Shaping tomorrow starts with today’s plans and strategies

A JOURNEY TOGETHER More than 250 team members have been with Shape for 15 or more years

FATHER’S VISION TO FAMILY LEGACY Chairmen of the Board, and Brothers, Tony and Kyle Verplank reflect on their journey from growing up alongside the company their father founded to leading Shape Corp. through its 50th milestone. Scan the QR code to watch this personal interview and discover how the Verplank family’s values have shaped the company’s path forward.

SHAPE ON THE R O L L · J A NUA RY 2025

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SHAPE ON THE ROLL

ANNIVERSARY SPECIAL EDITION

GIVING BACK WHEN GARY AND MIDGE VERPLANK STARTED THEIR COMPANIES, THEY MADE A PROMISE TO GIVE BACK TO THE COMMUNITY WHERE THEY WERE FOUNDED. “We are not the singular reason for the success of our companies,” said Midge in 2016. “We will make sure that our companies and ourselves participate in the well-being of the community that we live and work in.”

We’re thrilled to bring back Shape on the Roll with this special edition to mark Shape Corp’s 50th anniversary– a milestone year filled with celebration, reflection and anticipation.

We’ve honored this momentous occasion through fifty community service projects and vibrant festivals that united team members and their families across every region where Shape has a presence.

Join us as we celebrate the legacy, spirit, and shared achievements that have brought us to this moment and will guide us into the next fifty years.

Inside, you’ll discover a tribute to our founders, key historical milestones, our journey of growth and expansion, and an exciting look at how we’re shaping the future with innovative processes, sustainable practices, and cutting-edge technologies.

50 YEARS, 50 ACTS OF SERVICE: SHAPING OUR COMMUNITIES To celebrate this milestone year, Shape Corp. took on 50 community service projects, giving back to the communities that have supported us for the past five decades.

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Kids’ Food Basket Jingle Bell Parade Harvest Stand Ministries Adopt-a-Highway Habitat for Humanity Grand Haven Pride Festival YMCA Coast Guard Run Winterfest Kids’ Event Operation United with Veterans Earth Day Tree Giveaway United Way Campaign Community Action House YMCA Races - Kick Off Love in Action Campus Cleanup Kid’s Coast Guard Parade Day of Caring Tree Planting Holiday Family Sponsorship GLT Volunteering at Salvation Army Gleaners Food Bank Support United Way/Red Cross Sound the Alarm Nursing Home Painting Project Shared Harvest Food Bank Events Earth Day Trash Cleanup Clothing Donations Fort Trash Pickup Collection of Waste Plastic Packaging Book Donation Drive for Children Blood Donation Tree Plantation Bicycle Ride for Wetland Cleanup Haircuts & Health Checks for Elderly Summer Daycare / Factory Open Day Salute to Summer Outdoor Workers Donation of Office Supplies to Local Need Environment Cleanup Around Factory Nanhu Primary School Visit Riverbank Cleaning Activity Kunshan Forest Park Tree Adoption EHS Tree Planting Event Elderly Haircuts & Blood Pressure Checks Office Equipment Donation Floorball Charity Tournament Save the Bambies Initiative Nýrany City Run ANA Building Training Centre Water Rescue Lesson Benches for Nýrany City Children’s Olympics

PIONEERS. LEADERS. MENTORS. PRESIDENTIAL ROSTER

1984 PORTRAIT Picture of Shape’s founders outside the manufacturing facility on 1900 Hayes St. in Grand Haven, MI.

FINDING SHAPE From visionaries to pioneers, Shape founders laid the groundwork for innovation, growth and a culture that continues to inspire. gained momentum, the facility doubled in size, but the company was sold in 1969.

Nonetheless, Verplank and Pearson remained passionate about rollforming, and in 1974, they partnered with Bill Stevenson, Bob Currier Sr., Ron Kolkema, and Gary Verplank to start a new venture.

1978-1987

GARY VERPLANK

1987-1999

PETER STURRUS

1999-2011

TOM DEVOURSNEY

2011-2016

BOB CURRIER JR.

2016

MARK WHITE

Through their ambition and innovation, they ignited the spark of progress that has illuminated our path. Their legacy lives on in the very

Shape opened their doors for business on April 26, 1974. Working out of the original 14,400 ft2 Ferrysburg facility, the founders navigated early legal and management challenges then ultimately appointed Gary Verplank as President.

Gary’s engineering background positioned him well to steer Shape’s future.

GARY VERPLANK

Co-Founder 1940-2019 Gary, with a degree in Industrial Engineering from the University of Michigan, served as President and CEO, growing Shape into a global enterprise. He was deeply committed to his community, supporting numerous nonprofits and schools. Known for his humility, he was passionate about Shape’s team members and their families.

Alongside his brother, he was inducted into the West Michigan Business Hall of Fame in 2004.

Midge Verplank Robert Currier Sr. Ron Kolkema

Over the next 41 years, he led with a vision that solidified Shape’s industry standing and built a company culture rooted in his own values.

RON KOLKEMA

HEAR THEIR VOICES, THEIR WORDS

LEFT: 1966 – Tri-Cities Construction builds a new 7,700 ft² facility at 705 2nd St. in Ferrysburg, Mich.

RIGHT: Expanded to 14,400 ft² in 1968. Shape Corp. would occupy the facility in 1974 as their initial base of operations. In 1978, Shape moved into a new facility in Grand Haven located at 1900 Hayes St.

essence of Shape, in the values they instilled, and the principles they upheld.

As we celebrate our 50th anniversary, we honor the

memory of these pioneers, knowing that their spirit will continue to shape our future fifty years, just as it has defined our Founding Fifty.

IN MEMORIUM

Gary Verplank

WHERE IT STARTED:

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BILL STEVENSON

From Left to Right: Midge Verplank, Ron Kolkema, Bob Currier Sr., and Gary Verplank. Stuart Pearson and Bill Stevenson were also original founders but left the company in 1976 and 1978, respectively.

FOUNDING 50

Shape Corp. began as a bold vision to unlock the potential of rollforming, a revolutionary manufacturing process at the time. In 1966, Midge Verplank launched Coastal Rollform Inc. alongside Stuart Pearson, James Anderson, and Ted W. Clune, pooling their talents and resources to build a 7,200 ft2. facility in Ferrysburg, Michigan. As Coastal Rollform

1974-1978

In this remarkable journey, we pause to remember Shape’s founders and founding leaders­- those who have passed, and those who have retired.

Scan the QR code to watch a video of Shape’s founders—brothers Midge and Gary Verplank, along with longtime President Pete Sturrus—in this special video filmed in 2015.

They reflect on the vision, resilience, and innovation that shaped Shape Corp. A must-

see for anyone inspired by their legacy.

Co-Founder 1932-2007 Ron-co founded Shape and its subsidiaries, contributing significantly to the company’s early success. A Muskegon, Michigan native, Ron’s expertise was in manufacturing. His primary focus was getting quality product out the door and was instrumental in many early manufacturing advancements that set the foundation for what was to come.

MIDGE VERPLANK

Co-Founder 1931-2022 Midge was a visionary leader who founded and supported many businesses and charitable initiatives in Grand Haven. He believed that businesses exist to better the community and improve lives. Although never active in day-to-day management, Midge faithfully served on Shape’s Board of Directors for 48 years and generously used his resources to make a positive impact.

ROBERT CURRIER, SR.

Co-Founder 1924-1999 Bob was a key figure in Shape’s early days, leading up their sales efforts which helped get Shape off the ground. A WWII Navy pilot and University of Michigan graduate, he also co-founded Light Corp., Finish Corp., and Track Corp., playing a pivotal role in Grand Haven’s business community. His legacy reflects a dedication to innovation and ventures that shaped the region’s industrial growth. His son, Robert Jr., would lead Shape Corp. as President from 2011 to 2016.

PETER STURRUS

Past President 1933-2022 Pete was a creative leader who drove Shape’s entry into the automotive industry.

He invented the tubular rollformed bumper, a patented innovation that transformed Shape into a Tier 1 crash management leader. Pete remained passionate about engineering and the skilled trades. In 2017, he was instrumental in creating the Sturrus Technology Center at Muskegon Community College.

SHAPE ON THE R O L L · J A NUA RY 2025

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IN-LINE SWEPT BUMPER BEAM

MILESTONES ACROSS DECADES

A rollforming industry first that propelled Shape into the automotive market.

Shape’s revolutionary sweeping process made it more economical to add curvatures to high strength steel bumpers.

From humble beginnings to a global leader, explore the journey of Shape through the pioneering spirit of our founding decades.

1970s

1980s

1990s

2000s

2010s

2020s

1974: Company founded on April 26. Focus is on appliance and office furniture components.

1980: 1900 Hayes St. adds 36,000 ft²

1991: 1900 Hayes St. adds 124,000 ft²

2000: 14600 172nd Ave. adds 116,000 ft²

2022: Shapes opens new engineering and sales office in Novi, Michigan

1984: 1900 Hayes St. adds 57,000 ft²

1993: Shape opens the Japanese automotive market.

Receives first order from Honda

2001: NetShape founded.

Specializes in large tonnage plastic injection molding

2010: Shape Mexico established. 307,000 ft² manufacturing plant built in Queretaro, Mexico

1974: First production part made on Nov. 5th 1978: Shape moves into new 30,500 ft² facility in Grand Haven located at 1900 Hayes St.

1984: First parts made for automotive applications 1986: Finish Corp. founded.

Specializes in industrial painting 1986: Light Corp. founded.

Specializes in design and assembly of task lighting.

1988: 1900 Hayes St. adds 60,000 ft²

1995: Tech Center created as R&D hub at 1835 Hayes St. 1996: Pliant Plastics acquired.

Specializes in small tonnage plastic injection moldings 1996: Shape University founded to promote employee training and ongoing education.

1997: Shape builds 14600 172nd Ave. 1998: Detroit sales office opens in Madison Heights

2003: Shape opens Japan sales office located in Tokyo

2011: Shape Europe established. Manufacturing plant is in Pilsen, Czech Republic

2003: NetShape builds new 85,000 ft² facility at 16344 Comstock St. in Grand Haven

2016: New 105,000 ft² manufacturing facility opens in Athens, Alabama

2004: 1820 Hayes St. adds 90,000 ft² 2005: Shape acquires 1825 Industrial Dr. Grand Haven 2008: Shape China established.

335,000 ft² plant is in Kunshan 2008: Engineering office opened in Pune, India

2017: Shape China opens 51,000 ft² manufacturing facility in Guangzhou, China 2018: Magnode acquired.

Specializes in tight tolerance high strength aluminum extrusions 2020: Engineering and sales office opened in Munich, Germany

2023: Aluminum division opens new 320,000 ft² facility located in Trenton, Ohio 2023: European operations move into new 370,000 ft² facility located in Nyrany, Czech Republic 2023: New 174,000 ft² manufacturing facility opens in Huntsville, Alabama

3D Bending Technology The pinnacle of design freedom in rollforming to date. Shape developed the ability to bend advanced high strength steel tubular structures in any direction and across any plane.

ICONIC PRODUCTS

The iconic products that shaped the company ­— or at least have some good stories associated with them!

2024: Shape Corp. celebrates 50th anniversary

CURVED PULTRUSION

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Shape’s entry into composites was propelled by adding curvature to pultrusion - a historically straight process. The WILL PROJECT X EVER COME continuous process TO LIFE? utilized lightweight carbon fiber todercreate Tusci corroremquas hollow profiles chilliquo et quam ipietatet constant radii. optatur?

Ecus voluptusam velitius. Gitis reicide niscidebis modi ommolor umquiatem. Denis es ut eum int ipsae.

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f WILL PROJECT X EVER COME TO LIFE?COMPONENT TOOLBOX

SPARK OF INNOVATION In pa diorruptasit latis

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Tusci der1974corroremquas – Shape’s first production chilliquo et quam ipiet part, a component foret a toolbox, optatur?

Ecus was made onvoluptusam November 5, 1974. velitius. Gitis reicide niscidebis modi ommolor umquiatem. Denis es ut eum int ipsae.

In pa diorruptasit latis

innovation.

Every milestone molds and odis brought new trust Shape was founded on exces iure eostio. exces iure odis eostio. reflects our core values, in Shape’s innovation.

In a persistence, creativity, and Itatiatatur, sant aped ullita Itatiatatur, sant aped ullita from unyielding steel memorable pitch, Shape a belief in the potential of vel eici siti que vel mo quo velbending eici siti que vel mo quo to redefining designs with foundersipsae. even carried bumnew ideas. In the early days, ipsae. creativity. As we celebrate pers in ski bags to Japan—a it took ten months to secure our history, we also honor our first order—a wait that re- bold move that led to longthe iconic products that have term partnerships. These quired faith and commitment. defined Shape’s journey, moments represent our That first bumper order, each with its own story of infounders’ determination and though simple, changed the courage, qualities that contin- genuity, impact, and success. trajectory of Shape. Despite These products not only ue to define us as we dream, skepticism that the steel shaped our past but continue work, and grow together. was “too strong to bend,” to inspire the future of our Shape achieved what others innovations.

Through these pivotal thought impossible, proving moments, Shape Corp. our engineering capability. established more than just a business—it created a legacy One design, scribbled on a of resilience,SHAPE risk-taking, and napkin, broke conventional ON THE R O L L · J A NUA RY 2025

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TRENTON PLANT: PIONEERING ALUMINUM SOLUTIONS Shape’s new 330,000 ft2 facility in Trenton, Ohio, focuses on high-strength aluminum extrusions, leveraging advanced technologies to deliver innovative, lightweight solutions for the automotive industry.

FOUNDING 50

GROWTH & EXPANSION

AROUND THE WORLD Shape expanded globally to deliver industry-leading solutions, establishing a presence in Asia, Europe, and Mexico. Today, our international locations enable us to serve customers worldwide with the same commitment and culture that began in Michigan.

UNITED STATES

MEXICO

In the past five years, Shape has grown across the U.S. In 2022, we expanded our Novi, Michigan sales and tech center to better serve Detroit customers. In 2023, a state-of-the-art aluminum facility opened in Trenton, Ohio. In 2024, a second plant in Alabama opened.

Shape Mexico’s manufacturing plant opened in 2010, by 2015 it nearly doubled its production space to accommodate the high levels of production. In 2024, additional growth necessitated the construction of a second manufacturing operation in Querétaro.

From its beginnings in Ferrysburg, Shape steadily expanded from Grand Haven to Detroit, establishing a strong presence in Michigan — the heartland of automotive and office furniture manufacturing — building a solid foundation in the early decades.

Founded in Ferrysburg, Michigan, in 1974, Shape Corp. began as a modest enterprise with a bold vision. Over the past five decades, Shape has grown exponentially, becoming a trusted partner to the world’s leading automakers.

Headquartered in Grand Haven, Michigan, Shape now operates fourteen manufacturing plants and five tech centers globally, employing over 4,200 people.

As Shape celebrates its 50th anniversary, the commitment to innovation and growth is stronger than ever. In June 2024,

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Shape opened a 202,306 ft2 state-of-the-art facility in Huntsville, Alabama focused on lightweight crash management systems. Shape’s global footprint also expanded with a 392,000 ft2 facility in Nyrany, Czech Republic, reflecting the company’s goal of carbon neutrality by 2035.

NYRANY PLANT IN THE CZECH REPUBLIC, EST. 2023 Adhering to rigorous BREEAM New Construction environmental standards, this facility is 392,000 ft2 and is Shape’s second plant in the Czech Republic.

In Trenton, Ohio, the Aluminum Division celebrated a new 330,000 ft2 plant dedicated to high-strength aluminum extrusions. These expansions, alongside investments in technology and sustainability, highlight Shape’s unwavering commitment to customers, team members, and communities.

From its roots in Ferrysburg to becoming a global innovator, Shape continues to lead in advanced manufacturing.

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Today, Shape buildings span approximately 2 million ft2 around the world ASIA

EUROPE

Shape Asia established its presence in 2003 by opening an office in Japan. In 2008, the first global manufacturing plant was launched in Kunshan, China. To further boost production capacity in the region, a second plant was opened in Guangzhou in 2017 and a third in 2025.

In 2023, Shape Czech successfully transitioned its operations to a state-of-the-art, sustainable facility, certified as a BREEAM building. This new facility not only supports Shape’s sustainability goals but also provides a healthier and more eco-friendly working environment for everyone.

SHAPE ON THE R O L L · J A NUA RY 2025

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GLOBAL TEAM

ON THE FRONT LINES Representing Shape’s commitment to excellence, our Global Customer Teams work tirelessly, stay customer-centric, and embrace the fun and collaboration that define our culture.

SHAPE JAPAN The Shape Toyota office in Toyota City, Japan, opened in August, offers a modern, collaborative space designed to inspire creativity and productivity.

Featuring state-of-the-art facilities and sustainable design, it reflects Shape’s commitment to innovation, environmental responsibility, and advancing the company’s future vision..

DRIVING EXCELLENCE IN STEEL DESIGN Shape Celebrates Automotive Excellence Award for Advanced High-Strength Steel Innovation Shape Corp. has been recognized by the American Iron and Steel Institute at the 22nd Annual Great Designs in Steel symposium. Product Development Leader, Dave Seiter, received the prestigious Automotive Excellence Award alongside General Motors and Magna.

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This award honors our innovative application of advanced high-strength steel in the GMC Hummer EV SUV, showcasing our commitment to excellence and cutting-edge engineering. Congratulations to Dave and the entire team for their outstanding work and dedication!

SHAPE PARIS, FRANCE

SHAPE PUNE, INDIA

SHAPE MUNICH, GERMANY

Established in 2010, the Paris office has driven Shape’s European success, securing partnerships with Renault, Nissan, Stellantis, and Tesla.

Their collaboration across functions and team spirit shine, both professionally and personally, with weekend cycling adventures strengthening their bond.

Shape India, established in 2008 in Pune, has evolved into a vital Engineering Centre supporting global product realization. With expertise in advanced simulations, design, and development, the team contributes to key projects for leading OEMs like BMW, Renault, and Toyota.

Opened in 2019, Shape’s Munich office has secured key partnerships, including high-volume BMW programs. Located on the iconic Leopoldstrasse, the team excels in engineering and sales, earning high praise for execution. After work, they bond over Helles beer in the English Garden.

QUALITY AT THE CORE

Shape’s commitment to quality ensures customer satisfaction, strengthens trust, and drives continuous improvement across our operations.

Quality is the foundation of everything we do at Shape Corp., driving excellence in our products, services, and operations. During the Global Quality Summit 2024, we reaffirmed our dedication to exceeding customer expectations through continuous improvement and innovation.

A highlight of the Summit was an on-site workshop at the 172nd plant, where the Global Quality team performed a Reverse FMEA (RFMEA) on Tesla welders.

This hands-on activity yielded actionable insights, reinforcing our promise to deliver the highest standards to our customers.

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UPPER BODY STRUCTURE

FRONT & REAR STRUCTURE

FRONT FLOOR / BATTERY TRAY

Shape’s expertise in crafting pillars, roof panels, and side structures ensures robust protection and durability, enhancing the vehicle’s strength and overall safety from every angle.

With advanced high-strength frames and expertly engineered impact zones, Shape designs front and rear structures to absorb collision energy effectively, maximizing passenger protection..

Shape’s innovative battery trays and floor structures integrate seamlessly with electric vehicle energy systems, ensuring essential protection, weight efficiency, and long-lasting durability.

FUTURE 50

FUTURE 50 At Shape Corp., we’re driven by technology, innovation, and a collaborative spirit.

FUTURE 50 STRATEGIES Material Innovation Collaboration with Global OEMs Next Gen Vehicle Design Sustainable Products and Processes

SHAPING WHAT’S NEXT Engineered for tomorrow, Shape’s expertise in core vehicle systems enhances safety, efficiency, and innovation. From structural components to energy management solutions, we’re powering the next generation of safer, smarter vehicles.

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ED PLEET, CTO “At Shape, we’re delivering solutions built on a foundation of talented people working together to push the boundaries of automotive technology.”

Over the past 50 years, we’ve evolved from a local rollforming company into a global leader in automotive solutions. What defines us—and what will continue to drive us forward—is our team’s commitment to creating technologies that others can’t.

Today, Shape’s mission is more important than ever. We’re working with OEMs worldwide, delivering advanced solutions that offer weight savings and enhanced safety, all while keeping costs competitive.

From our new aluminum center of excellence in Trenton, Ohio, to our high-tech facility in the Czech Republic, we’re positioned to provide our customers with both steel and aluminum

options that meet the industry’s highest standards.

Our expertise in safety systems, honed over decades as bumper specialists, now extends to the entire vehicle. Whether it’s the intricate rollforming of highstrength materials or creating complex extrusions, we’re advancing automotive technology in ways that directly enhance vehicle safety and performance.

Electric vehicles, autonomy, and smarter manufacturing processes are all part of our roadmap, enabling us to offer unparalleled value to our customers.

Our talented team members, who embody Shape’s culture of creativity and integrity, work closely with our partners to develop unique, market-leading solutions. We’re building on the legacy of our founders, who instilled a spirit of teamwork and innovation that still guides us.

As we look to the future, we’re confident that this culture will keep us moving forward— together, as a Shape family.

Sincerely, Ed Pleet Chief Technology Officer Shape Corp.

SHAPE ON THE R O L L · J A NUA RY 2025

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PIONEERING PRODUCT AND PROCESS TECHNOLOGY:

REVOLUTIONIZING WELD TESTING FOR EFFICIENCY AND PRECISION

Combining Collaborative Robotics with Advanced Ultrasound Technology

At Shape Corp., innovation is not just about developing new products—it’s about improving every step of our processes. With Spot Sight, we are transforming the way weld testing is conducted, ensuring faster, more accurate, and safer operations across our facilities.

FUTURE 50

BEYOND BUMPERS: SHAPE CORP.’S LEADERSHIP IN VEHICLE LOAD PATH MANAGEMENT Advancing Technologies Across the Entire Vehicle Structure At Shape, we have expanded our reputation as experts in bumper systems to encompass the entire load path of the vehicle—a framework critical to managing impact energy and optimizing occupant safety. With decades of innovation in impact energy management, we are driving advancements that redefine crashworthiness and elevate vehicle design.

MASTER OF IMPACT ENERGY MANAGEMENT The load path represents how forces are distributed across a vehicle during impact.

By understanding how energy flows from the impact area to the body structure, we ensure that every structural component contributes to occupant safety.

Our use of computer-aided engineering (CAE) software and advanced optimization techniques allows us to strike the perfect balance of performance, mass, and cost. This holistic perspective allows Shape to provide high value solutions to our customers that exceed safety and efficiency standards, providing comprehensive solutions for modern vehicle designs.

As we enhance our load path expertise,

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we are also exploring additional areas including the potential of smart structures.

These systems have the potential to offer revolutionary capabilities such as damage assessments and high-resolution crash detection.

In material innovation, we are exploring alternatives to aluminum castings, such as consolidating components into single structures. Leveraging our expertise in plastics and engineering, Shape is well-positioned to develop advanced processes that align with trends driven by leading OEMs.

DRIVING THE FUTURE OF AUTOMOTIVE DESIGN Shape’s focus on load path management underscores our dedication to safety, performance, and innovation. By

integrating advanced technologies and exploring transformative processes, we are setting a new standard for the industry.

Our vision is clear: to lead not just in bumper systems but across the entire structural framework and load path of the vehicle. Through these efforts, we continue to provide forward-thinking solutions that meet the evolving demands of our customers and redefine the future of automotive engineering.

Manual weld testing has long been a time-consuming and labor-intensive process.

Operators had to destructively measure welds using calipers, a method that was not only inefficient but also prone to human error. As vehicle designs evolve and demand higher precision, it became clear that a more reliable, automated solution was necessary.

The Spot Sight system, powered by the Fanuc CRX10 collaborative robot, redefines weld testing by integrating advanced robotics with ultrasound technology.

Here’s how it works:

IR/3D VISION: The system uses integrated infrared and 3D vision to precisely locate each weld. This ensures accurate placement of the ultrasonic probe on the target weld.

ULTRASONIC TESTING: Spot Sight employs distilled water as a medium to transmit ultrasound waves through a membrane, eliminating the need for traditional gel. This eco-friendly method ensures consistent and reliable testing without additional cleanup.

COLLABORATIVE DESIGN: Operating at safe speeds, the Fanuc CRX10 requires no addition-

al guarding, allowing human workers to operate alongside the robot without risk.

This collaborative approach simplifies integration into existing workflows and eliminates the need for extensive safety barriers.

As we continue to innovate, we are committed to adopting advanced solutions that not only streamline our processes but uphold the highest standards of safety and quality.

TRANSFORMING LOGISTICS WITH AUTONOMOUS MOBILE ROBOTS Driving Efficiency and Safety in Modern Manufacturing Operations

One of our most impactful advancements is the implementation of Autonomous Mobile Robots (AMRs) in our logistics workflow. These compact yet powerful robots are revolutionizing how materials move within our facilities, ensuring seamless coordination between production and shipping.

Before introducing AMRs, our logistics relied on manual

tugger trains—a laborintensive system prone to inefficiencies. The decision to automate was driven by a clear vision: to increase operational efficiency, reduce human workload, and maintain safety standards across three shifts of production.

Shape Corp. began its AMR journey in the Czech Republic with four robots, operating five days a

week with occasional overtime. These robots perform 80-90 missions per shift, transporting empty containers from the shipping area to production and returning with full containers.

The introduction of AMRs has also enabled greater standardization in Shape’s logistics operations. The robots ensure consistent service rates between production and shipping,

reducing variability and allowing for better planning and execution.

As we continue to expand our AMR capabilities, Shape Corp. remains committed to being at the forefront of manufacturing innovation, ensuring that our facilities operate at peak performance while maintaining the highest safety standards.

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PIONEERING PRODUCT AND PROCESS TECHNOLOGY: FUTURE 50

SUSTAINABLE MATERIAL ADVANCEMENTS

BREAKING NEW GROUND WITH BUMPER BEAM TECHNOLOGY Redefining Rollforming: Pioneering Tight-Radii Innovation in Ultra-High-Strength Steel

Shape has made a major leap forward in rollforming with the development of a new, tight-radii bumper beam. In response to our customers’ demand for tighter swept bumper beams, we’re excited to introduce our latest development—an inline variable, tight-radius sweeping technology capable of curving martensitic bumpers to meet challenging new targets.

This innovation allows for continuous rollformed profiles

to extend further outboard beyond the front rail without compromising vehicle styling. This technology not only meets stringent safety standards but also offers significant cost and weight savings for our automotive partners.

“This project propels Shape to the forefront of rollforming technology, offering unprecedented capabilities in speed, strength, and efficiency,” says a member of our engineering team, says Joe Matecki, Advanced

Product Development Engineer at Shape Corp.

Driving a Greener Future: Pioneering Advancements in Sustainable Materials and Manufacturing

By collaborating with Meta Tool Technologies (MTT) and Shape’s simulation experts in India, this project exemplifies a global effort in design and prototyping. Initial trials have shown remarkable results, with line speeds doubled and improved adaptability in response to high-speed demands. This achievement aligns with Shape’s commitment to exceeding the evolving demands of OEM customers worldwide.

ADVANCING WITH FOSSIL-FREE STEEL: A FIRST IN AUTOMOTIVE MANUFACTURING In partnership with Sweedish steel company, SSAB, Shape has become the first in the industry to manufacture a rollformed martensitic steel bumper utilizing SSAB’s fossil free steel. This groundbreaking material, produced with hydrogen rather than coal, showcases our dedication to utilizing the latest advancements in material science while reducing the industries reliance on fossil fuels.

NETSHAPE SOLUTIONS GROUP: PLASTICS INNOVATION

Reestablished as an independent entity, NetShape has a renewed focus on customer-centric innovation Earlier this year, Shape Corp. took a bold step to enhance its focus on the plastics and composites industry by reestablishing its plastics business as an independent entity, NetShape Solutions Group. This strategic move marks a return to the roots of NetShape, which was originally founded as a sister company nearly 25 years ago, dedicated to delivering high-value, innovative solutions to customers.

Over the years, Shape integrated NetShape into its broader operations to drive efficiencies

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across its metals and plastics divisions. However, the increasing complexity and specialization of the plastics market presented an opportunity to reignite NetShape’s independence. By relaunching as a separate entity, NetShape is now poised to bring sharper focus, agility, and innovation to the industry, empowering the business to achieve its full potential.

Jason Meyer, a seasoned leader within Shape, has taken the helm as President of NetShape Solutions Group. Under his guidance, NetShape will continue to push

boundaries with a dedicated focus on engineering, manufacturing, quality, and customer-centric solutions. This specialized approach aims to position NetShape as a premier provider in the plastics industry, offering unparalleled value to customers worldwide.

The creation of NetShape Solutions Group highlights Shape Corp.’s ability to evolve while staying true to its innovative spirit.

This move underscores a broader theme woven throughout Shape’s 50-year history—continuous

transformation to better serve its customers and set new standards in the industries it touches. NetShape Solutions Group is not just a return to the company’s roots; it is a launchpad for the future of plastics innovation.

“Our collaboration with SSAB has set a new standard for the application of cutting-edge materials in vehicle manufacturing,” explains Brian Oxley, Project Manager.

This partnership demonstrates Shape’s mastery of rigorous material testing, including fracture characterization and welding evaluations, ensuring that fossil-free steel performs on par with or exceed current standards.

PUSHING THE LIMITS WITH ALUMINUM ROLLFORMING Shape’s collaboration with Novelis has ushered in a new era of lightweight, complex aluminum automotive parts. By utilizing high strength 6xxx and 7xxx aluminum alloys, Shape has expanded its capability to create efficient, sustainable and cost-effective automotive structures such as rockers, roofbows and battery tray crossmembers.

“Offering the ability to rollform complex shapes can be a game-changer for aluminum automotive

components,” notes Brian Oxley. “Our work with Novelis opens new possibilities, allowing us to produce complex geometries that enhance structural efficiency without the need of a secondary process.

By minimizing the need for multiple stamping and assembly operations, Shape’s aluminum rollforming approach not only maximized efficiency, but also allows OEMs to enjoy greater design flexibility and reduced production costs.

ROOTS OF SUSTAINABILITY: BENEFITS OF ROLLFORMING MATERIAL UTILIZATION

By optimizing material usage through rollforming, we minimize waste and reduce the environmental footprint. Rollforming ensures that more of the material contributes to the final product.

HIGH STRENGTH MATERIAL

Rollforming allows for the precise shaping of high-strength material, providing superior strength-to-weight ratios. This not only enhances the structural integrity of components like bumpers, but also reduces the overall weight of the vehicle.

EFFICIENT GEOMETRY

Rollforming enables the creation of complex geometries with precision, reducing the need for additional processing steps. This efficiency not only cuts down on manufacturing time and costs, but also reduces energy consumption.

SHAPE ON THE R O L L · J A NUA RY 2025

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LEADING US INTO THE NEXT CHAPTER Get to know the Shape Greater Leadership Team

MARK WHITE

FUTURE 50

SHAPING A GREENER TOMORROW

As Shape looks to the future, our commitment to sustainability is stronger than ever—from reducing our carbon footprint to innovating with cleaner materials.

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ENVIRONMENTAL

SOCIAL

GOVERNANCE

Shape Corp. is committed to reducing emissions, waste, and environmental impact while striving for carbon neutrality.

Shape prioritizes inclusivity, wellness, and community impact to empower people and build stronger connections.

Shape upholds ethical standards, accountability, and transparency to drive sustainable and responsible governance.

Carbon Reduction, Energy Efficiency: • Offset 42% of global electricity consumption in 2023 with 85,000+ renewable energy certificates • Opened BREEAM-certified, stateof-the-art facility in the Czech Waste Management Progress: • Diverted 80% of manufacturing waste from landfills through recycling and sustainable disposal • Reduced water consumption by nearly 30 megaliters in 2023 despite increased production Product and Process Innovation: • Developed ultra-high-strength steel and lightweight aluminum 20 • Introduced injection molding resins with up to 70% recycled content

Employee Wellness and Inclusivity: • Promoted wellness programs and created an inclusive workplace celebrating diversity Encouraging Future Generations: • Partnered with schools for STEM outreach, scholarships, and mentorship programs Community Engagement: • Team members volunteered 4,000+ hours globally in 2023 • Supported local conservation efforts, youth organizations, and philanthropic projects

Commitment to Ethical Standards: • Adhered to strong governance policies and compliance with industry regulations • Participated in the Carbon Disclo sure Project, showing yearly improvements since 2022 Accountability and Transparency: • Published regular sustainability reports to track progress and uphold transparency Upholding High Standards: • Prioritized responsible supply chain practices and data security • Embodied leadership in creating a sustainable future for all

President and CEO Mark is responsible for vision, executing growth strategies and delivering business performance. With 30+ years in automotive, he is committed to Shape culture and creating exciting growth opportunities for the team. Mark enjoys time on Lake Michigan, skiing and traveling with family.

JASON MEYER

President, NetShape Jason Meyer started his Shape career in 1998 and recently transitioned to take on the role of President at NetShape. Jason thrives on solving challenges, enabling team growth, and connecting with his family.

AYMERIC HOMMEL

Managing Director, Europe Division Aymeric brings extensive global leadership experience to Shape, with a focus on innovation, cultural collaboration and operational excellence across Europe. Fluent in German and English, Aymeric also has a tremendous passion for cooking.

AIDA TANAKA

General Counsel Aida leverages years of manufacturing legal expertise to solve business challenges at Shape. A Cleveland native, she fell in love with Grand Haven during her first interview and enjoys the local social scene.

GUSTAVO OROZCO

Managing Director, Mexico Division Gustavo joined Shape in 2020 with nearly two decades of automotive experience. A graduate in Industrial Engineering, Gustavo enjoys running, swimming, and spending quality time with his wife and two children.

MIKE LIETO

Managing Director, US Division Mike brings extensive financial and leadership expertise to Shape.

Outside of work, Mike enjoys sports, running, family time, and grilling on his Big Green Egg, always supporting the University of Michigan.

TONY VERPLANK

Executive Chairman Tony has dedicated his career to Shape, serving in leadership roles across operations, manufacturing, and business units. A Michigan State graduate, Tony enjoys gardening and supporting his community while driving Shape’s strategic vision.

DAVE GUARESIMO

Chief Operating Officer Dave has led operations across the globe driving productivity and quality improvements through metric driven leadership.

A Purdue engineering grad with an MSU MBA, Dave is fluent in Spanish and Portuguese.

DARIC MORELL

KYLE VERPLANK

Executive Chairman Kyle first started at Shape as a high school student working summers on the shop floor, joining full time in 2006. He has held various roles and was appointed to his current in 2019. A Michigan grad with an MBA from Pepperdine, Kyle enjoys sailing, skiing, and family travel.

ED PLEET

Chief Technology Officer Ed brings expertise in vehicle structures and global product development, honed during his time living and working in Shanghai, China. Outside of work, he cherishes the busy time with his wife Jennifer and their four children.

MIKE MENKE

Chief People Officer Daric leads Shape’s people strategy, applying his engineering background from MSU and operational expertise. He enjoys sailing, paddleboarding, and hiking. Daric is committed to fostering a thriving workplace culture at Shape.

Chief Financial Officer Mike brings financial expertise honed at Whirlpool and Shape, with a focus on strategic planning and supplier management. An MSU graduate, Mike enjoys golf, family time, and traveling with his wife and two sons.

RYAN DEBOER

ALEX GAO

Managing Director, Managing Director, Aluminum Division Asia Division Ryan’s has a passion Alex joined Shape in for transforming raw 2008 as Plant Manager of materials into finished its first overseas facility products, leading in Kunshan, China. With him to study Plastics a strong engineering Engineering at Ferris background and over State. His leadership 12 years of industry focuses on enabling team experience, Alex leads success, continuous with a passion and SHAPE ON THE R O L L · J A NUA RY 2025 21 improvement, and enjoys bicycling, movies, fostering innovation. and aquariums.

ANNIVERSARY CELEBRATION

GLOBAL 50 ANNIVERSARY FESTIVALS TH

PROUD TO SHOW & TELL PLANT TOURS Some Shape festivals featured facility tours and product displays, showcasing the parts and vehicles they help build, inspiring pride in families.

In every region, Shape Corp. marked its 50th Anniversary with vibrant festivals that honored our past and looked boldly to the future.

The plant tour stood out as one of the festival’s most memorable moments. Employees proudly guided their families through Shape’s cutting-edge operations.

Autonomous mobile robots (AMRs), robotic weld cells, and advanced manufacturing equipment were all on display.

In honor of Shape’s 50th anniversary, every division across the world gathered for a festival like no other.

From North America to Europe and Asia, each region hosted its own unique celebration, bringing together Shape team members, their families and retirees.

Many Shape team members took the lead, pointing out and explaining various parts of the plant. For them, it was a special moment—sharing their work with loved ones, and watching as their families left with newfound pride in the incredible work they do.

SHAPE JAPAN

SHAPE INDIA

Shape 50th Anniversary Celebration took place at Shape Japan in February. The celebration featured an elegant dinner, fun games, and thoughtful gifts for both team members and their families. This milestone was made even more special as it also marked 20 years of 22 Shape’s presence in Japan.

Shape India celebrated Shape’s 50th Anniversary in a vibrant style, joined by team members and their families.

The event featured delicious food, lively performances, and energetic dancing, making it a truly joyful and unique occasion.

JAPAN

INDIA

With thousands in attendance at each event, the festivals were a testament to Shape’s global reach and the strong sense of community that unites us.

Each division took ownership of their celebration, weaving in elements that reflected both their local culture and Shape’s founding and future-focused themes. The

“Founding 50” tributes honored our rich history and the visionary leaders who built our foundation, while the “Future 50” exhibitions showcased our latest innovations and bold aspirations for the decades ahead.

From live entertainment and food to hands-on demonstrations of our innovative technologies, these celebrations captured the spirit of Shape— one rooted in connection, progress, and the joy of shared achievements.

Across every region, the festivals were a reminder of what we’ve built together and a bold look at the road ahead.

SHAPE ON THE R O L L · J A NUA RY 2025

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PLANT TOUR Team members conducted several plant tours to show all families our processes and how our team members are key to our success.

ANNIVERSARY CELEBRATION

ANNIVERSARY CELEBRATION

GRAND HAVEN, MI, USA

QUERETARO, MEXICO

50 YEARS LATER

At Shape Mexico, the

To Celebrate Shape’s 50 Anniversary in Michigan, the 2024 Shape Festival took place in Grand Haven.

celebration took place in Querétaro’s plant where the event featured a mariachi band,

Celebrating 50 years of history in the place where everything started was an incredible milestone that marks a promising future based on a rich and successful history for our company.

A selection of local food trucks, a variety of fun games, and joyful gifts were highlights of the celebration.

TRENTON, OH, USA 24

Mexican ballet, games, and train rides for families to tour the plant and learn about the processes and facilities that Shape Mexico offers.

MEXICAN STYLE The day was brimming with Mexican tradition, vibrant colors, lively dance, and festive music. In Shape Mexico, this was a dual celebration, as Shape Querétaro also marked the 20th anniversary of its establishment.

Celebrating at the headquarters, where everything started 50 years ago.

But what truly made the event special was the opportunity to meet each other’s families and spend quality time together, capturing the warm spirit of the Shape Family culture that has been built through these 50 years.

TRENTON COMMUNITY AFFAIR Shape Trenton hosted the 2024 Shape Festival at its new facility, offering plant tours, auto exhibits showcasing aluminum products, food trucks, live music, and games. Team members and families enjoyed a memorable day, with the Mayor and city council joining to celebrate Shape’s achievements and community impact.

SHAPE ON THE R O L L · J A NUA RY 2025

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ANNIVERSARY CELEBRATION SPORTS

GAMES

ENTERTAINMENT

SHAPE SONG

In Czech Republic team members celebrated Shape’s 50th Anniversary at a sports complex in Pilsen.

Numerous sports stations and attractions for both adults and children were featured at the celebration.

To warm up in the cold weather, the Shape Czech team performed a drumsticks choreography.

As an inspiring way to mark this milestone anniversary, the Shape Czech team debuted the first-ever Shape song during the event.

KUNSHAN, CHINA

Celebrating Shape’s 50th anniversary in the Year of the Dragon sets the stage for growth and prosperity for the next 50 years.

ANNIVERSARY CELEBRATION

PILSEN, CZECH REPUBLIC Making memories that will pave the way for another 50 years of development, enthusiasm, success, and fun.

THE FIRST CELEBRATION IN 2024 Shape China kicked off this series of global events with a spectacular annual party featuring various cultural performances while highlighting and recognizing the incredible contributions of our China Division team members

YEAR OF THE DRAGON As 2024 began, Shape China set its sights on overcoming challenges and achieving success in this legendary Year of the Dragon.

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SHAPE ON THE R O L L · J A NUA RY 2025

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PRSRT STD US Postage Paid Permit No. 1 Grand Rapids, MI

15+ Years of Service

A JOURNEY TOGETHER

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