![]() ![]() With their porous structural lattice, the ceramic bricks are a cost-effective building material, since they are much lighter and use less raw material than conventional solid bricks, and would be useful in large-scale constructions. Research on the PolyBrick project, she said, focused on “the prospect of building part-to-whole assemblies featuring non-standard components and biologically inspired forms.” To our knowledge, we were the first to do this.” “I was interested in using the printer to rapid manufacture non-standard parts for larger architectural assemblies instead of representational models. “I started working with 3-D printing in 2009 when we were able to purchase our first ZCorp 510 powder-based printer … the largest powder-based printer on the market at the time,” Sabin said. ![]() In turn, this creates openness at the top of the assembly where desired to maximize the filtration of light,” Sabin and Miller said.Įntire buildings can be constructed using a single material, and there is almost no waste in the 3-D printed production of the bricks. The thickness of the lattice may be tapered towards the top of the structure to add reinforcement at the base where it is needed. This awareness allows this aggregative system to implement proper taper angle to ensure gravity will lock the bricks in place.”ĭata from various sources is used to tune the structural lattice of each brick, and can be used for “everything from structural optimization to view angles, porosity, curvature and form, to the strategic placement of plumbing and mechanical building systems. Within this algorithm, there is also a global awareness of the components’ orientation in Euclidean space. ![]() “At the local scale, there are geometric manipulations and exchanges built into the algorithms connecting components with their adjacent neighbors. “Each brick/component has an embedded intelligence at both the local and global scales,” Sabin and Miller said in a joint statement. ![]() PolyBricks feature tapered dovetail joints like those used in woodworking, and the tapered sides of the bricks can be oriented in wall assemblies to maximize structural strength. … 3-D printing allows us to build and design like nature does, where every part is different, but there is a coherence to the overall form at a global scale.” “It will allow for the production of ceramic wall assemblies that are robust and high strength due to the novel implementation of highly complex and organic generative design strategies that are also simply and economically produced. “PolyBrick is the first mortarless, 3-D printed wall assembly,” Sabin said. Using 3-D printing and advanced geometry, a team at Cornell has developed a new kind of building material – interlocking ceramic bricks that are lightweight, need no mortar and make efficient use of materials.ĭeveloped by the Sabin Design Lab in collaboration with Cornell and Jenny Sabin Studio, the PolyBrick project team included assistant professor of architecture Jenny Sabin with senior research associate Martin Miller, a visiting critic at Cornell visiting lecturer Andrew Lucia and Nicholas Cassab, B.Arch. The ceramic bricks after one firing are shown at right. PolyBricks are created on a 3-D printer as greenware, at left, and then fired. ![]()
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