Plexus Sistem Sambuangan by Subinay Malhotra

Plexus Sistem Sambuangan by Subinay Malhotra is a highly esteemed winner of the very prestigious 2025 A' Design Award Basi in Generatif Competition Category.

BasiGeneratif· 2025

Plexus Sistem Sambuangan

by Subinay Malhotra

Client: Subinay Malhotra Designworks

A' Design Award Basi Winner in Generatif Category

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Verified Award Winner

Verify Award Status for #171156

View at A' Design Award Press Release Award Badge

Colors

The Design

About Plexus Sistem Sambuangan

Plexus marupokan sistem sambuangan modular nan dicipto jo desain generatif sarato konektor nan dapek disasuaikan. Sistem iko manyambuangkan bagian-bagian tanpa manggunokan pengencang tradisional, sahinggo mambanyo peralihan nan muluih antaro parmukaan sarato struktur. Komponen-komponen dihasilkan malalui proses lost-wax casting dari pola lilin nan dibuek jo teknologi pencetakan 3D. Jaringan algoritmik mampakuek titiak-titiak tekanan sarato mangurangi jumlah logam nan dipakai. Proses anodizing nan bardampak randah sarato pelapisan nan indak baracun mampaelok daya tahan sarato kualitas parmukaan. Plexus mandukuang proses pamasangan sarato pangaturan baliak untuak sagalo macam pemakaian.

The Recognition

About the A' Design Award Basi

Plexus Sistem Sambuangan adolah pamenang A' Design Award Basi, sabuah pangakuan nan bapresti nan dibarikan ka rancangan nan elok nan mamanuhi kaparluan profesional jo industri nan dipaokan dari ciptaan nan dirancang jo elok. Pamenang Basi mamparlihatkan kamahiran nan gadang, spesialisasi nan tinggi, pamahaman pakar jo kapasitas kreatif panciptanyo. Plexus Sistem Sambuangan dipaokan manjadi ciptaan nan sangaik dihormati, dikagumi jo disayangi, nan praktis jo inovatif. Rancangan nan manang Basi iko mamasukkan praktik tabaik industri jo punyo ciri teknis nan cakap nan bapautan jo ilimu jo bakaik. Plexus Sistem Sambuangan dihormati karano katalitiannyo jo dirancang untuak maningkekkan kualitas hiduik jo mambantu manjadikan dunia tampek nan labiah elok.

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