Units, Joints, Forms

Overview

This project investigates how a single modular unit can multiply into a flexible design system.

Through joint optimization, pattern exploration, and iterative assembly, the unit adapts into various configurations—planar, folded, and volumetric forms.

The work combines digital fabrication and hands-on prototyping to explore how geometry, material behavior, and connection logic drive form-finding.

Gallery

Unit prototype – single module test

Unit assembly – early interlocking attempt

Circular arrangement – planar aggregation study

Modular ring – radial configuration test

Planar cluster – multi-unit configuration

Dense planar assembly – connection behavior study

Semi-spherical prototype – vertical stacking attempt

Curved aggregation study – emerging dome formation

Small sphere prototype – early closed volume

Open dome structure – hybrid planar-curved assembly

Illuminated sphere – light transmission study

Module color test – mixed units demonstration

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Design Goals

Create a repeatable yet expressive modular unit.
Develop a joint system balancing bespoke geometry with repeatable fabrication.
Explore how modular aggregation produces morphological effects—curvature, density, volume.
Test feasibility through rapid prototyping and material iteration.

Process

1. Geometry Exploration

Early sketches and digital drawings investigate circular morphologies and interlocking branches.

Different unit topologies were tested to understand how they aggregate and deform.

2. Geometry Exploration

Early sketches and digital drawings explore circular morphologies and branching connections.

Different unit topologies were tested to understand how they aggregate and deform.

test

3. Digital Pattern Development

Units were drawn in Illustrator and refined through multiple iterations.

Joint proportions, slot tolerances, and material constraints were optimized through parametric adjustments.

5. Assembly & Form-Finding

Through stacking, layering, and clustering, diverse morphologies emerged:

planar tessellations
soft curvature
shell-like enclosures
volumetric forms wrapping around light sources

The same geometry adapts dramatically depending on how units interact.

6. Morphological Effects / Final Outcomes

Unit 1–3 → simple planar clusters
Unit 4–5 → emerging curvature
Unit 9+ → dense, volumetric shell formations

Under lighting, the surfaces generate layered shadows and nested geometries, enhancing spatial depth and visual density.

4. Material Experiments & Joint Prototyping

Using Zünd cutting, laser cutting, and occasional 3D printing, a series of physical prototypes evaluated:

flexibility & bending behavior
friction-fit strength
durability across materials
assembly feasibility and tolerance control

These tests refined the joint logic and verified structural behavior.

Morphological Effects

The system demonstrates a wide range of expressions:

Unit 1–3: simple planar clusters
Unit 4–5: emerging curvature
Unit 9+: dense structures and volumetric shells

These transformations highlight the adaptability of the modular language.

Play of Forms

Under lighting, the unit produces layered shadows and nested geometries.

The modular aggregation interacts with illumination, creating dynamic spatial effects.

Workflow Diagram

Pattern illustration of modular units
Material experiments & cutting
Joint modeling (3D printing if applicable)
Parts assembly
Feasibility & structural testing