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US researchers at Cornell University have developed a 3D printed interlocking brick system that does not require mortar and which they say can be used to construct entire buildings and other large-scale structures.
The “Polybricks” are hollow lattice structures made of ceramic that are locked together by tapered dovetail joints like those used in woodworking. 3D printing the structures enables designers to minimise waste and costs.
Structures are designed using Computer Aided Design / Computer Aided Manufacturing processes and printed on a Zcorp 510 powder-based printer.
Computer algorithms devised by the team “tune” the structural lattice of each brick so that the direction and severity of the tapering enables the maximum lock between the bricks. The structural lattice can also be changed to change curvature and form, as well as allow for the placement of mechanical and electrical building systems.
Jenny Sabin, from the Sabin Design Lab, said: “Each brick has an embedded intelligence at both the local and global scales. At the local scale, there are geometric manipulations built into the algorithms connecting components with their adjacent neighbours. There is also a global awareness of the components’ orientation in Euclidean space. This awareness allows this aggregative system to implement proper taper angle to ensure gravity will lock the bricks in place.”
After printing the bricks are fired in a low bisque fire which decreases warping and shrinkage. They are then dipped in a high fire satin glaze. Once glazed, the bricks are fired at a higher temperature to ensure the glaze vitrifies. They can then be assembled.
The research team is working to improve the design and printing process. Sabin said: “Polybrick will allow for the production of ceramic wall assemblies that are robust and high strength. 3D 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.”