Flatpack Foldable Structural Connections

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IMG_20220520_165427_364

Flat | Fold Joinery

grasshopper, rhino, mild steel

status : on-going

Prototyping a rigorous and elegant system for assembling timber frameworks using custom-fabricated steel connectors. Drawing from principles of modularity and precision-fit manufacturing, the project introduces a family of bracket typologies that enhance structural integrity while celebrating the expressive potential of exposed joinery. The result is a refined hybrid of industrial pragmatism and crafted minimalism.

Designed and prototyped in Rhino, and fabricated using RhinoCAM, each connection is derived from a parametric model that allows variations in joint angles, material thicknesses, and wood member sizes. The steel components were cut from flat sheets using a CNC plasma cutter, then hand-bent and drilled where necessary to achieve their final form. The fabrication logic respects the constraints of 2D nesting and the efficiencies of material use while leveraging the performative strength of folded geometry.

Each bracket integrates seamlessly with dimensional wood members, locking them together at precise angles without requiring complex joinery cuts in the wood itself. In contrast to traditional mortise and tenon or doweled connections, these steel plates externalize the joinery, making the method of assembly visible and aesthetically intentional. The fasteners, standard hex bolts and locking nuts, are recessed into the plate patterns with a studied regularity that contributes to the overall visual discipline of the system.

The joinery was conceived not only as a means of structural fastening but also as a language of spatial and material articulation. By using planar steel components and minimal bending operations, the project achieves a high degree of repeatability and scalability, making it ideal for prefabricated or on-site assembly contexts. The connection system enables a kit-of-parts approach, where disassembled structures can be flat-packed for transport and rapidly reassembled without loss of precision or integrity.

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Process

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More Work

Architecture

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  • SA Architects

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  • Pawtucket Day Nursery

    pawtucket, rhode island

  • Meeting Street Center for Excellence

    providence, rhode island

  • Norterly Island Nature Center

    Chicago, Illinois

  • National Institute of Flamenco

    old town plaza, santa fe, new mexico

  • Corrales Comunity Pathway + Pedestrian Park

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  • The Construction of Art

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Design + Fabrication

  • Flatpack Foldable Structural Connections

    rhino, grasshopper, mild steel

  • Renegades

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  • Surface Flux

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  • Acoustic Diffusion Panel

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  • Hyperbolic Bending

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    python, c#, grasshopper, wood, plasti-dip, carbon, gelatin

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  • The God of Skiing

    book design

© [wpsos_year] Ken Marold USA, Inc. All rights reserved.

Continue reading

Renegades: Bruce Goff and the American School of Architecture

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featured

Renegades

Bruce Goff and the American School of Architecture

grasshopper, rhino, cnc, pla, corrugated cardboard

status : complete

Joined exhibition team as principle fabricator for all furniture and signage components in the exhibit. Components developed include:

  • nine 8′ tall typographic elements,
  • nine 9′ long freestanding workstations,
  • one 32′ long bench,
  • three architectural drawing display tables ranging in length from 7-12′
  • one virtual reality workstation
  • four stools

Initiated fabrication, construction, joinery, and material research used for developing a novel assembly system and production workflow for creating of a collection of furniture pieces and large-scale objects using honeycomb cardboard and wood.

Subsequent R+D resulted in a provisional patent :

Marold, K., Honeycomb Cardboard Edge Insert Component that Creates a Reinforced, Rigid Edge and Continuous Connection Surface Allowing for Crush-Resistant Edges and Continous, High Surface Area, Edge-to-Face and Edge-to-Edge Fastening of Multiple Honeycomb Parts, ID Number: 62/954,239, Patent Type: Provisional, Application: December 19, 2019, Approved: December 27, 2019.

Also developed and instructed a supporting student fabrication seminar titled ” Topological Ecotones”

The work produced in this seminar were also included in the Fred Jones exhibit.

Ecotones are transitional regions that bridge two distinct biological communities, for example, the zone between a forest and grassland. As such an ecotone contains overlapping characteristics of two biomes, and often contain a mixture of plant and animal species from each adjacent ecosystem. Ecotones are patchworks, edge conditions and are typically more dynamic biologically and topographically than their adjacent communities. In your design investigations you will identify and develop digital processes that explore distinct topographical conditions that amplify and articulate these edge conditions. These unique ecotones can push against the boundaries of earthly terrains and explore hypothetical, other-worldly terrains. In so much of the work done by American School architects, there is also a presence of distinct material ecosystems that converge in dynamic and energetic ways, creating architectural ecotones in their own right. In keeping with this spirit, our work will explore particular topics of tectonic intersection, connections with nature and topographical extremes.

TOUR THE EXHIBIT

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Process

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More Work

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    python, grasshopper, rhino, 3d printing

  • Recursive Paneling

    laser cut mylar

  • Sweet Crude

    python, c#, grasshopper, wood, plasti-dip, carbon, gelatin

  • Ruling Lines

    laser cut cell cast acrylic, stainless steel braided wire

  • Volumetric Aggregations

    processing, grasshopper, rhino, cast acrylic, black walnut, hickory

  • Cellulose Bookcase

    pine, black walnut, compressed wood fiber board, stain

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    rhino, pla, birch plywood

  • Andraditic Mass

    arduino, firefly, rhino, 3d printed pla, baltic birch plywood

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  • Folding Attractors

    grasshopper. rhino, white museum board

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    rhino, cnc milled birch plywood

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    grasshopper, rhino, hickory

  • Infiltration Table

    processing, spalted birch plywood, poplar, enamel, lacquer

Art + Code

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  • Surface Flux

    python, c#, grasshopper, pla, wood, steel

  • Dixieland Death Cult

    acrylic, plywood

  • Approximation of a Generation

    private tremendous

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© [wpsos_year] Ken Marold USA, Inc. All rights reserved.

Continue reading

Additive Manufactured Structural Connection

Written by on . Posted in Design + Fabrication. Leave a Comment

IMG_20220104_093159_927

Carbon Fiber Connections

grasshopper, rhino, pla, carbon fiber

status : on-going

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Process

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More Work

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    rhino, grasshopper, mild steel

  • Renegades

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    python, c#, grasshopper, pla, wood, steel

  • Carbon Fiber Connections

    grasshopper, rhino, pla, carbon fiber

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    grasshopper, rhino, cnc, rigid insulation

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    grasshopper, rhino, laser cut acrylic, bristol board

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    python, grasshopper, rhino, 3d printing

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    laser cut mylar

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    python, c#, grasshopper, wood, plasti-dip, carbon, gelatin

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    laser cut cell cast acrylic, stainless steel braided wire

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    processing, grasshopper, rhino, cast acrylic, black walnut, hickory

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    pine, black walnut, compressed wood fiber board, stain

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    rhino, pla, birch plywood

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    grasshopper, rhino, black walnut

  • Folding Attractors

    grasshopper. rhino, white museum board

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    rhino, cnc milled birch plywood

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    grasshopper, rhino, hickory

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    processing, spalted birch plywood, poplar, enamel, lacquer

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© [wpsos_year] Ken Marold USA, Inc. All rights reserved.

Continue reading

The God of Skiing

Written by on . Posted in Design + Fabrication. Leave a Comment

god-of-skiing_1-1

The God of Skiing

book design

status : complete

  • cover

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  • god-of-skiing_1-2

  • god-of-skiing_1-3

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More Work

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    pawtucket, rhode island

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    providence, rhode island

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    Chicago, Illinois

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    old town plaza, santa fe, new mexico

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    corrales, new mexico

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    Santa Fe, New Mexico

Design + Fabrication

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    rhino, grasshopper, mild steel

  • Renegades

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  • Surface Flux

    python, c#, grasshopper, pla, wood, steel

  • Carbon Fiber Connections

    grasshopper, rhino, pla, carbon fiber

  • Acoustic Diffusion Panel

    grasshopper, rhino, cnc, rigid insulation

  • Hyperbolic Bending

    grasshopper, rhino, laser cut acrylic, bristol board

  • Filtration : Infiltration

    python, grasshopper, rhino, 3d printing

  • Recursive Paneling

    laser cut mylar

  • Sweet Crude

    python, c#, grasshopper, wood, plasti-dip, carbon, gelatin

  • Ruling Lines

    laser cut cell cast acrylic, stainless steel braided wire

  • Volumetric Aggregations

    processing, grasshopper, rhino, cast acrylic, black walnut, hickory

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    pine, black walnut, compressed wood fiber board, stain

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    rhino, pla, birch plywood

  • Andraditic Mass

    arduino, firefly, rhino, 3d printed pla, baltic birch plywood

  • Cholla

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  • Folding Attractors

    grasshopper. rhino, white museum board

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    rhino, cnc milled birch plywood

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    grasshopper, rhino, hickory

  • Infiltration Table

    processing, spalted birch plywood, poplar, enamel, lacquer

Art + Code

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© [wpsos_year] Ken Marold USA, Inc. All rights reserved.

Continue reading

Gonzo Cubes

Written by on . Posted in Art + Code, Design + Fabrication. Leave a Comment

featured-01

Gonzo Cubes

solidity, html, css, javascript, illustrator

status : on-going

Gonzo Cubes are 10,000 uniquely generated digital collectibles living on the Polygon blockchain.

Each Gonzo Cube is unique and programmatically generated from over 570 possible traits, including expressions, headwear, accessories, body and leg parts, fillings, specials, suprises and more. Every cube is gonzo, but some are more gonzo than others.

Owning a cube gives you an unprecedented advantage and exclusive access to a growing number of members-only benefits.

They’re cute, kind of gritty, pretty twisted, not afraid to get nasty, and always up for gonzo challenges. Gonzo Cubes are tough little nuggets and ready to jump into our first play to earn game launching in the Gonzopolis metaverse, Gonzo Fight Club (Q2/2023). Battle other cubes for dominance, rule the scoreboard and leave with the biggest stake!

Gonzo Cubes are built to serve community, gaming and utility oriented projects. We want all Gonzo Cube holders to have access to exclusive benefits that are rewarding and fun and that’s why we’re bringing our best ideas to the table when it comes to growing our ecosystem and elevating our community.

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  • 87 – Copy

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  • 2

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  • 5

  • web_assets

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    rhino, grasshopper, mild steel

  • Renegades

    Fred Jones Jr Museum of Art

  • Surface Flux

    python, c#, grasshopper, pla, wood, steel

  • Carbon Fiber Connections

    grasshopper, rhino, pla, carbon fiber

  • Acoustic Diffusion Panel

    grasshopper, rhino, cnc, rigid insulation

  • Hyperbolic Bending

    grasshopper, rhino, laser cut acrylic, bristol board

  • Filtration : Infiltration

    python, grasshopper, rhino, 3d printing

  • Recursive Paneling

    laser cut mylar

  • Sweet Crude

    python, c#, grasshopper, wood, plasti-dip, carbon, gelatin

  • Ruling Lines

    laser cut cell cast acrylic, stainless steel braided wire

  • Volumetric Aggregations

    processing, grasshopper, rhino, cast acrylic, black walnut, hickory

  • Cellulose Bookcase

    pine, black walnut, compressed wood fiber board, stain

  • Asher Chair

    rhino, pla, birch plywood

  • Andraditic Mass

    arduino, firefly, rhino, 3d printed pla, baltic birch plywood

  • Cholla

    grasshopper, rhino, black walnut

  • Folding Attractors

    grasshopper. rhino, white museum board

  • Grain Chair

    rhino, cnc milled birch plywood

  • Tracking Parallelograms

    grasshopper, rhino, hickory

  • Infiltration Table

    processing, spalted birch plywood, poplar, enamel, lacquer

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    book design

© [wpsos_year] Ken Marold USA, Inc. All rights reserved.

Continue reading

Steel + Light

Written by on . Posted in Design + Fabrication. Leave a Comment

Untitled-1

Steel + Light

Convergence Arts Festival Masterwork

providence, rhode island

status : complete

A collaboration with Hogan + Macaulay Architects, this project was conceived as a cinematic montage that explores the use of light as a medium to ‘drape’ imagery across the Providence Hurricane Barrier.

The imagery selected and the compositional choices made for this exhibition included body parts, such as arms, hands and faces, as well as photographs of dancers juxtaposed with more abstract imagery. The entire exhibit was initially simulated on formZ using the exact lighting specs, distances, surrounding light pollution levels, and physical properties to gain insight on our design choices but also to point out any environmental factors that might challenge our preconceptions.

The goal was to create a visual dialog between projected elements of the human form and the highly engineered structural elements of the Hurricane Barrier. The result exceeded our expectations as the dual 12,000 lumen light canons cast intensely vibrant imagery upon the Hurricane Barrier’s three story volumes and lacy structural assemblies, cutting through lightly foggy fall nights over the Narragansett Bay.

  • Untitled-1

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More Work

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    pawtucket, rhode island

  • Meeting Street Center for Excellence

    providence, rhode island

  • Norterly Island Nature Center

    Chicago, Illinois

  • National Institute of Flamenco

    old town plaza, santa fe, new mexico

  • Corrales Comunity Pathway + Pedestrian Park

    corrales, new mexico

  • CRCUIT

    albuquerque, new mexico

  • The Construction of Art

    providence, rhode island

  • Santa Fe Univeristy School of Fine Arts

    Santa Fe, New Mexico

Design + Fabrication

  • Flatpack Foldable Structural Connections

    rhino, grasshopper, mild steel

  • Renegades

    Fred Jones Jr Museum of Art

  • Surface Flux

    python, c#, grasshopper, pla, wood, steel

  • Carbon Fiber Connections

    grasshopper, rhino, pla, carbon fiber

  • Acoustic Diffusion Panel

    grasshopper, rhino, cnc, rigid insulation

  • Hyperbolic Bending

    grasshopper, rhino, laser cut acrylic, bristol board

  • Filtration : Infiltration

    python, grasshopper, rhino, 3d printing

  • Recursive Paneling

    laser cut mylar

  • Sweet Crude

    python, c#, grasshopper, wood, plasti-dip, carbon, gelatin

  • Ruling Lines

    laser cut cell cast acrylic, stainless steel braided wire

  • Volumetric Aggregations

    processing, grasshopper, rhino, cast acrylic, black walnut, hickory

  • Cellulose Bookcase

    pine, black walnut, compressed wood fiber board, stain

  • Asher Chair

    rhino, pla, birch plywood

  • Andraditic Mass

    arduino, firefly, rhino, 3d printed pla, baltic birch plywood

  • Cholla

    grasshopper, rhino, black walnut

  • Folding Attractors

    grasshopper. rhino, white museum board

  • Grain Chair

    rhino, cnc milled birch plywood

  • Tracking Parallelograms

    grasshopper, rhino, hickory

  • Infiltration Table

    processing, spalted birch plywood, poplar, enamel, lacquer

Art + Code

  • Prairie Fire

    acrylic, ink, plywood

  • Surface Flux

    python, c#, grasshopper, pla, wood, steel

  • Dixieland Death Cult

    acrylic, plywood

  • Approximation of a Generation

    private tremendous

  • Elemental Worlds

    science museum oklahoma

  • Gonzo Cubes

    solidity, html, css, javascript, illustrator

  • A Line of Force

    arduino, grasshopper, firefly, java, plywood

  • The Drift

    html, css, javascript

  • Gear Institute

    illustrator, photoshop, php, css, html

  • Prism

    unity, c#, spine2d, illustrator

  • Squall

    petroglyphs national monument, albuquerque, new mexico

  • Galileo’s World Interactive

    c#, unity3d, illustrator, photoshop

  • Steel + Light

    convergence arts festival masterworks project, providence, rhode island

  • The God of Skiing

    book design

© [wpsos_year] Ken Marold USA, Inc. All rights reserved.

Continue reading

Gear Institute

Written by on . Posted in Design + Fabrication. Leave a Comment

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Gear Institute

illustrator, photoshop, php, css, html

status : complete

Outdoor Gear + Adventure Website and Mobile App. Gear Institute was founded in 2012 on the idea that  outdoor enthusiasts deserved a better tool to help them buy the best outdoor gear for them.

Outdoor gear is expensive. The technologies are complicated. And the marketing spin is laid on thick. In many cases, the right gear can make for a comfortable, safe experience or a miserable, dangerous one. You should not have to parse page upon page of marketing fluff and reviews by amateur “gear reviewers” to help you find affordable gear you can rely on.

Gear Institute is a network of the best outdoor gear testers in America, dedicated to providing the most credible, objective, and helpful reviews and buying advice you can find on the web. Guides, veteran product testers, and top-level outdoor athletes put each product through extensive field testing against comparable products to provide you with clear, trustworthy, consumer-friendly comparisons of high-performance outdoor gear.

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More Work

Architecture

  • Wichita Mobile Clinic

    anadarko, oklahoma

  • SA Architects

    cranston, rhode island

  • OKC Greenhouse

    oklahoma city, oklahoma

  • Pawtucket Day Nursery

    pawtucket, rhode island

  • Meeting Street Center for Excellence

    providence, rhode island

  • Norterly Island Nature Center

    Chicago, Illinois

  • National Institute of Flamenco

    old town plaza, santa fe, new mexico

  • Corrales Comunity Pathway + Pedestrian Park

    corrales, new mexico

  • CRCUIT

    albuquerque, new mexico

  • The Construction of Art

    providence, rhode island

  • Santa Fe Univeristy School of Fine Arts

    Santa Fe, New Mexico

Design + Fabrication

  • Flatpack Foldable Structural Connections

    rhino, grasshopper, mild steel

  • Renegades

    Fred Jones Jr Museum of Art

  • Surface Flux

    python, c#, grasshopper, pla, wood, steel

  • Carbon Fiber Connections

    grasshopper, rhino, pla, carbon fiber

  • Acoustic Diffusion Panel

    grasshopper, rhino, cnc, rigid insulation

  • Hyperbolic Bending

    grasshopper, rhino, laser cut acrylic, bristol board

  • Filtration : Infiltration

    python, grasshopper, rhino, 3d printing

  • Recursive Paneling

    laser cut mylar

  • Sweet Crude

    python, c#, grasshopper, wood, plasti-dip, carbon, gelatin

  • Ruling Lines

    laser cut cell cast acrylic, stainless steel braided wire

  • Volumetric Aggregations

    processing, grasshopper, rhino, cast acrylic, black walnut, hickory

  • Cellulose Bookcase

    pine, black walnut, compressed wood fiber board, stain

  • Asher Chair

    rhino, pla, birch plywood

  • Andraditic Mass

    arduino, firefly, rhino, 3d printed pla, baltic birch plywood

  • Cholla

    grasshopper, rhino, black walnut

  • Folding Attractors

    grasshopper. rhino, white museum board

  • Grain Chair

    rhino, cnc milled birch plywood

  • Tracking Parallelograms

    grasshopper, rhino, hickory

  • Infiltration Table

    processing, spalted birch plywood, poplar, enamel, lacquer

Art + Code

  • Prairie Fire

    acrylic, ink, plywood

  • Dixieland Death Cult

    acrylic, plywood

  • Approximation of a Generation

    private tremendous

  • Elemental Worlds

    science museum oklahoma

  • Gonzo Cubes

    solidity, html, css, javascript, illustrator

  • Surface Flux

    python, c#, grasshopper, pla, wood, steel

  • A Line of Force

    arduino, grasshopper, firefly, java, plywood

  • The Drift

    html, css, javascript

  • Gear Institute

    illustrator, photoshop, php, css, html

  • Prism

    unity, c#, spine2d, illustrator

  • Squall

    petroglyphs national monument, albuquerque, new mexico

  • Galileo’s World Interactive

    c#, unity3d, illustrator, photoshop

  • Steel + Light

    convergence arts festival masterworks project, providence, rhode island

  • The God of Skiing

    book design

© [wpsos_year] Ken Marold USA, Inc. All rights reserved.

Continue reading