Plexus Joinery by Subinay Malhotra |
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| DESIGN NAME: Plexus PRIMARY FUNCTION: Joinery INSPIRATION: Inspired by nature’s seamless connections and biological structures, Plexus reimagines traditional joinery through generative design and modular adaptability. The project stems from parametric design, biomimicry, and material efficiency research, seeking to eliminate rigid fasteners in favor of fluid, scalable connections. By integrating algorithmic modeling with precision engineering, Plexus introduces a versatile, reconfigurable system that adapts across multiple applications. UNIQUE PROPERTIES / PROJECT DESCRIPTION: Plexus redefines modular joinery by integrating generative design with adaptable connection systems, allowing seamless transformation into various applications. Its innovative joining method enables fluid transitions between surfaces and structures, eliminating conventional fasteners while enhancing strength, flexibility, and scalability. Combining advanced metal treatments with precision-engineered connections, Plexus challenges traditional assembly processes by giving reconfigurable solutions OPERATION / FLOW / INTERACTION: Plexus utilizes an algorithmically generated mesh structure within its modular joinery system, ensuring optimal strength and weight distribution. The mesh is parametrically designed to reinforce stress points, allowing the structure to withstand significant loads while maintaining a lightweight, organic form. This adaptive approach enables seamless assembly, transformation, and reconfiguration without traditional fasteners, enhancing structural integrity, user interaction, and aesthetic fluidity in a scalable design solution. PROJECT DURATION AND LOCATION: The project started in August 2024 and was produced by February 2025. Plexus Joinery has been published globally, receiving recognition across various platforms. |
PRODUCTION / REALIZATION TECHNOLOGY: Plexus utilizes 3D-printed wax patterns combined with lost-wax casting to achieve intricate, high-precision modular joinery. The generative design is first developed through parametric modeling, then translated into wax prototypes via SLA 3D printing. These wax models undergo investment casting, producing durable metal components with seamless, organic forms. The system integrates custom anodization, electroplating, and multi-material hybridization, enhancing surface properties, durability, and aesthetic adaptability, redefining traditional joinery through advanced computational fabrication techniques. SPECIFICATIONS / TECHNICAL PROPERTIES: 218mm x 175mm x 162mm TAGS: generative design, modular joinery, parametric modeling, lost-wax casting, eco-friendly plating, sustainable manufacturing, computational fabrication, adaptive structures, material efficiency, algorithmic mesh RESEARCH ABSTRACT: Plexus is based on experimental design research exploring algorithmic joinery and modular assembly, with a focus on reducing unnecessary metal use through optimized material distribution and eco-friendly plating techniques. The objective was to create a seamless, reconfigurable connection system that enhances efficiency, sustainability, and adaptability. Using parametric modeling and computational simulations, the study analyzed load distribution and material behavior to eliminate excess material in non-critical areas. Data was gathered through digital stress tests and 3D-printed prototypes, refined via lost-wax casting and advanced metal treatments. Participants included engineers, designers, and fabricators, who provided insights into usability, strength, and scalability. The research demonstrated that generative mesh structures strategically reduce metal usage while maintaining structural integrity. Additionally, eco-friendly plating techniques, such as low-impact anodization and non-toxic electroplating, were integrated to enhance durability and environmental sustainability. This innovation enables sustainable manufacturing, minimizing waste while enhancing performance and flexibility. The impact extends to product design, architecture, and adaptive manufacturing, offering an efficient, high-performance alternative to traditional joinery. CHALLENGE: The biggest challenge in Plexus was balancing structural integrity with material reduction while maintaining seamless adaptability. Algorithmic joinery required extensive computational testing to optimize mesh density for load-bearing efficiency without overusing metal. Overcoming manufacturing constraints in lost-wax casting and eco-plating demanded collaboration with fabricators to refine tolerances. Bridging generative design with real-world production was key to making Plexus both scalable and sustainable. ADDED DATE: 2025-02-28 19:22:16 TEAM MEMBERS (1) : Subinay Malhotra IMAGE CREDITS: Image #1: Plexus Joinery Image #2: In Context Image #3: In context Image #4: In context Image #3: Function |
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NAME: Subinay Malhotra Designworks PROFILE: Subinay Malhotra is an Assistant Professor of Industrial Design at Iowa State University, specializing in AI-driven design, generative systems, and computational fabrication. With over 11 years of global industry experience, he has worked with leading brands, including Samsung Electronics, Google, Boeing, Bose, and OLA Electric, contributing to cutting-edge innovations in human-computer interaction, UX, and industrial design. His research focuses on leveraging AI, smart technologies, and advanced manufacturing to enhance user experience, accessibility, and sustainability. Subinay’s work explores the intersection of AI-driven design automation, parametric modeling, and universal design, particularly in assistive products and future-facing manufacturing techniques. His approach integrates human-centered research, adaptive product development, and digital tools, challenging conventional methods to create scalable, personalized, and sustainable solutions. He is also actively involved in curriculum development, fostering the next generation of designers through courses on AI in design, UX, and digital fabrication. His projects, including Plexus, investigate the evolution of modular systems, material optimization, and AI-assisted fabrication, pushing the boundaries of how technology can transform product design and user interaction. |
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Plexus Joinery by Subinay Malhotra is Winner in Generative, Algorithmic, Parametric and AI-Assisted Design Category, 2024 - 2025.· Read the interview with designer Subinay Malhotra for design Plexus here.· Press Members: Login or Register to request an exclusive interview with Subinay Malhotra. · Click here to register inorder to view the profile and other works by Subinay Malhotra. |
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