1. First Idea

For this process, I set my self the goal to create an truncated octahedron by using only one element for the interlocking system. 

Initially, I found it challenging to visualize how such a complex shape could be constructed from just one element. Therefore, I began by making sketches to get a better understanding of what such an element might look like. Soon, I came up with the idea to base the interlocking system on the principle of a zipper. This technique enabled me to interlock a hexagonal element with teeth to form a truncated octahedron.

2.1 First Try

The next step was to model this interlocking part in 2D using Rhino. Subsequently, I had my interlocking part cut out using a laser cutter from a 3mm thick MDF board. My excitement after the first successful attempt was immense. The individual parts could be assembled into a truncated octahedron as planned. However, the interlocking parts were very loose, and the shape could not hold together on its own.

2.2 Second Try

Initially, I planned to integrate teeth on only three sides of the hexagon. Although this allowed me to construct a truncated octahedron, it was not possible to extend the interlocking system any further. In light of this issue, I developed the idea of adding teeth to all sides of the hexagon so that the truncated octahedrons could be connected to form a larger structure. I then implemented my idea and optimized the spacing between the individual teeth. After several test prints, my final part was created.

Design Choice

The special feature of this element is its ability to form multiple shapes. In designing this part, I was inspired by honeycombs. Later, I developed another idea for the design: I inserted a geometric spiral into the interior of the part. However, I noticed that this caused the overall aesthetics to be compromised. I took a step back and decided to leave an open space within the interlocking element in order to preserve the honeycomb aesthetics.

In addition to the laser-cut model, I created a rendered 3D view of the interlocking elements to test the functionality of the plug-in system.

Conlusion

I struggled a lot with Rhino in the beginning, so in the end I am very proud of my final result. During this course, I not only designed an awesome plug-in system, but also gained more experience with Rhino.