Plexus 접합 시스템 by Subinay Malhotra is a highly esteemed winner of the very prestigious 2025 A' Design Award 철상 in 제너레이티브, 알고리즘, 파라메트릭 및 AI 보조 디자인 Competition Category.

철제너레이티브· 2025

Plexus 접합 시스템

by Subinay Malhotra

Client: Subinay Malhotra Designworks

A' Design Award 철상 Winner in 제너레이티브 Category

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The Design

About Plexus 접합 시스템

플렉서스(Plexus)는 제너레이티브 디자인과 적응형 커넥터로 구현한 모듈형 접합 시스템이다. 이 시스템은 전통적인 파스너 없이 부재를 결합하여 표면과 구조 사이의 매끄러운 전환을 가능하게 한다. 구성 부품은 3D 프린팅으로 제작한 왁스 원형을 이용한 로스트왁스 주조 방식으로 생산된다. 알고리즘 기반 메시 구조가 응력 집중부를 보강하는 동시에 사용되는 금속량을 절감한다. 저부하 아노다이징과 무독성 도금 처리는 내구성과 표면 품질을 향상시킨다. 플렉서스는 다양한 응용 분야에서 조립과 재구성을 유연하게 지원한다.

The Recognition

About the A' Design Award 철상

Plexus 접합 시스템, 이 작품은 A' Design Award 철상 수상작으로, 잘 디자인된 창작물에 기대되는 전문적·산업적 요건을 충족하는 좋은 디자인에 수여되는 권위 있는 인정입니다. 철상 수상작은 창작자의 뛰어난 기술, 높은 전문성, 전문가다운 이해, 창의적 역량을 보여 줍니다. Plexus 접합 시스템, 이 작품은 높이 평가받고 감탄과 사랑을 받는 창작물로서 실용적이고 혁신적일 것으로 기대됩니다. 이 철상 수상 디자인은 업계 모범 사례를 통합하며 노하우와 재능으로 연결된 유능한 기술적 특성을 갖추고 있습니다. Plexus 접합 시스템, 이 작품은 철저함으로 존중받으며 삶의 질을 개선하여 세상을 더 나은 곳으로 만들도록 디자인되었습니다.

Behind the Design

Press Kit

Credits, team members and technical details provided by the designer.

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
Dimensions & Packaging: 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
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.
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.
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.
Team Members: Subinay Malhotra
Image Credits: Image #1: Plexus Joinery
Image #2: In Context
Image #3: In context
Image #4: In context
Image #3: Function