Researchers based at Sabin Design Lab, Jenny Sabin Studio and Cornell University have developed a new method of 3D printing large-scale forms of customized digital tools, low cost printing materials, as well as 3D printed interlocking component based systems referred to as PolyBricks.

PolyBricks are nonstandard high-resolution ceramic bricks that are quite similar to cinder blocks, although they do not require any mortar or additional adhesives. The research team turned to traditional wood joinery techniques as the means to interlock adjacent components, as well as develop customized tapered dovetail shapes that lock the bricks onto each other.

A customized tapered dovetail was developed in which the severity and direction of tapering depends on the local geometric orientation of every component. In this way, the tapering of the dovetail is based on the slope of the surface that is being generated such that the tapering’s narrow end is always at the lower face of the surface that is generated. As such, the adjacent components are locked together by the force of gravity.

The PolyBricks are designed to be hollow such that they use the material and time involved in an efficient manner. They are also designed to contain holes that will guarantee the removal of interior loose clay powder during post processing.

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Bill Besim