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.

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