Plexus

Joinery for Subinay Malhotra Designworks

Plexus introduces a new approach to modular joinery through the use of generative design and adaptable connectors. This system allows parts to be joined without traditional fasteners, enabling smooth transitions between components and structures. Designed for diverse applications, it enhances structural strength, flexibility, and material efficiency. With advanced metal treatments and eco-conscious processes, Plexus offers a sustainable, reconfigurable solution for evolving product and spatial needs.

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Plexus by Subinay Malhotra

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Joinery by Subinay Malhotra

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Subinay Malhotra Plexus

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Subinay Malhotra Joinery

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Unique Properties

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

Tags

generative design, modular joinery, parametric modeling, lost-wax casting, eco-friendly plating, sustainable manufacturing, computational fabrication, adaptive structures, material efficiency, algorithmic mesh

Production 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.

Design 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.

Project Duration

The project started in August 2024 and was produced by February 2025. Plexus Joinery has been published globally, receiving recognition across various platforms.

Operation Flow

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.

Research

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.

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.

Image Credits

Image #1: Plexus Joinery Image #2: In Context Image #3: In context Image #4: In context Image #3: Function

Project Overview

Plexus Joinery has been a Iron winner in the Generative, Algorithmic, Parametric and AI-Assisted Design award category in the year 2024 organized by the prestigious A' Design Award & Competition. The Iron A' Design Award is awarded to good designs that meet the rigorous professional and industrial standards set by the A' Design Awards. This recognition is reserved for works that demonstrate a solid understanding of design principles and show creativity within their execution. Recipients of the Iron A' Design Award are acknowledged for their practical innovations and contributions to their respective fields, providing solutions that improve quality of life and foster positive change. These designs are a testament to the skill and dedication of their creators, showcasing their ability to address real-world challenges through thoughtful design.

Iron Recognition

Subinay Malhotra was recognized with the coveted Iron A' Design Award in 2025, a testament to excellence of their work Plexus Joinery.

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