Plexus: Redefining Modular Joinery Through Generative Design

Nature-inspired innovation transforms traditional connections in architecture and design

Inspired by the seamless connections found in nature and biological structures, Plexus challenges the norms of traditional joinery. Subinay Malhotra’s vision draws from parametric design and biomimicry, aiming to eliminate rigid fasteners in favor of fluid, scalable connections. This approach leverages algorithmic modeling and precision engineering, resulting in a system that adapts effortlessly across multiple applications, from furniture to architectural structures.

The unique strength of Plexus lies in its innovative joining method, which enables fluid transitions between surfaces and structures. By integrating generative design with adaptable connection systems, Plexus eliminates the need for conventional fasteners, enhancing both strength and flexibility. Advanced metal treatments and precision-engineered connectors further distinguish the system, offering reconfigurable solutions that challenge traditional assembly processes.

Plexus is realized through a sophisticated combination of 3D-printed wax patterns and lost-wax casting, allowing for intricate, high-precision modular joinery. The process begins with parametric modeling, which is translated into wax prototypes using SLA 3D printing. These are then cast into durable metal components, featuring seamless, organic forms. Custom anodization, electroplating, and multi-material hybridization enhance surface properties and durability, setting a new standard for computational fabrication in joinery.

Functionality is at the core of Plexus’s design. The system utilizes an algorithmically generated mesh structure to optimize strength and weight distribution. This mesh is parametrically tailored to reinforce stress points, enabling the structure to withstand significant loads while maintaining a lightweight, organic form. The result is a joinery system that supports seamless assembly, transformation, and reconfiguration—without the need for traditional fasteners—enhancing both user interaction and structural integrity.

Research and development for Plexus focused on reducing unnecessary metal use and promoting sustainability. Digital stress tests and 3D-printed prototypes informed the optimization of material distribution, while eco-friendly plating techniques, such as low-impact anodization and non-toxic electroplating, were integrated to minimize environmental impact. The outcome is a high-performance, sustainable alternative to traditional joinery, with applications spanning product design, architecture, and adaptive manufacturing.

Recognized with the Iron A' Design Award in 2025, Plexus stands as a testament to the power of generative design and sustainable innovation. By bridging the gap between digital modeling and real-world production, Plexus offers a flexible, efficient, and environmentally conscious solution for the evolving needs of contemporary design and architecture.