In this project, I designed an interlocking construction system inspired by organic patterns found in nature, such as ginkgo leaves, coral reefs, cacti, and branching trees. These natural forms shaped the development of a modular structure composed entirely of two-dimensional elements. Using Rhino, I translated these inspirations into digital designs, which were then refined through multiple iterations and laser-cut from MDF. The resulting 40 components form a versatile system that assembles into three-dimensional configurations without the need for external tools or fasteners. The project emphasizes both aesthetic expression and structural functionality, achieved through simple interlocking connections. The design process was supported by a combination of analog sketching, digital modeling, and hands-on experimentation.
Analog Sketches & Rhino Model
This project began with a series of hand-drawn sketches exploring form and connection. I initially considered various geometric systems, including circles and organic shapes like leaves. Eventually, I was drawn to nature-inspired motifs and realized that a quarter-circle resembled the fan-like shape of a ginkgo leaf. This became the basis for my modular unit. When stacked and interlocked, these forms not only reference the structure of ginkgo leaves but also evoke coral reefs and branching systems found in nature.
Using Rhino, I developed the final design and laser-cut 40 individual pieces from MDF. The resulting elements interlock through sightly concave cut slots, requiring no adhesives or fasteners. I had originally considered adding surface patterns, but decided against it in favor of allowing negative space to play a stronger role. The open slots and radial cutouts naturally let light filter through, creating dynamic shadows and enhancing the sculptural quality of the piece.
Trial and Error
In the early stages of this project, I laser-cut several test pieces to evaluate the design and structural logic of my interlocking system. These first versions revealed multiple issues: the overall scale was too small, the pattern cuts were positioned too close to the edges and slots, and the resulting elements were fragile. The most critical problems occurred in pieces with multiple slots, particularly the ones with three, where narrow segments repeatedly broke under minimal pressure.
To address these weaknesses, I increased the size of the elements and adjusted spacing around high-stress areas. However, further testing showed that the one-slot pieces remained too delicate, and the two-slot pieces were still too narrow in the middle. These refinements highlighted the importance of balancing visual intricacy with structural integrity. Each iteration pushed the design toward greater durability without compromising the natural, fan-like aesthetic. Through this hands-on experimentation, I developed a more robust, visually coherent system that could be successfully assembled into a three-dimensional form.
The final System
After multiple rounds of testing and refinement, I arrived at a successful version of the design. I ultimately laser-cut 40 final pieces from MDF, each featuring slots that are 2.9 mm wide and slightly concave to ensure a snug, stable fit. The structure assembles entirely without tools or fasteners, relying purely on friction and precise interlocking. The final form exhibits an expressive, upward flow, provoking both organic growth and lightness. The entire process, from initial sketching and digital modeling to hands-on experimentation, resulted in a sculptural system that balances structural integrity with natural inspiration.
