Kevin Rustagi

Brick Intro- Conceptualization

So, I found this design challenge very interesting, in that it was pretty open-ended and had some
constraints. The bricks were to be made of dirt,, we were modifying a certain size, and ultimately, the
structure constructed out of them had to have some kind of structural integrity.

Step 1: Conceptualization: I brainstormed different 3d tessellations, starting off with the basic lego idea.
Extrude the top, and cut the absence of that from the bottom. I got further in to corner designs and
other issues there. I thought about how I might make the interlocking and tried my best to stray away
from, the idea of multiple different bricks, so as to minimize the amount of molds. I sought to achieve a
simple and easy to construct design that required only 1 mold. After a little over a few hours of ideating,
I came upon the plus design, which has some interesting prototyping properties. It can definitely handle
corners in that half of it is symmetric on both the x and y axes. The plus design involves a plus and plus
absence stamped onto each side of the brick, pressed into its former shape (see attached drawings). I
would be concerned that in the box mold, if not stamped, that the pegs would not come out easily. This
might be rectified by stamping, though definitely running tests on that would be good.

Brick Prototype Analysis

The prototype functions of the brick are interesting. Quick note, before I built it, so that I could better
see what I was looking at, I mocked it up in Solidworks. (Drawings and concepts are attached.) This
prototype is unfortunately very difficult to construct in foam, and will actually be much easier to make
using the actual mold, I think.

Since I had the cross and cross-absence pattern and that is virtually uncuttable with a band saw and/or
hot wire, I had to build it in components. Granted that had to happen, I sought to make it in the most
straight forward way that would allow for approximations.

Because I cut down the brick platform and added on the crosses and blocks (for the absences)and I then
used double-sided tape, and/or hot glue to adhere the shapes to the platform, one can approximate the
lateral force held by this brick (sheer) to be about as much as would be handle if the brick were
continuous. I feel that in this way, the brick is able to be used for some structural testing.

Quick note: When I cut the platforms, I made them only 7 cm, which caused a design skew. Now the
pegs had to be rectangular (actually a smaller square to handle both orientations 2.33 cm sq.) This just
goes to show, that one should have extra material and always measure carefully when building models.
I decided that it still proved my concept, even though it wasn’t as clean and then the bricks weren’t as
well fitting (more sliding give.)

I say, some structural testing because, I mean, you can test how well the bricks lock together using it.
However, certain differing material properties do and don't allow other analogies. As far as
performance goes, you wouldn't really be able to test the load as the dirt bricks would weigh more,
especially if you wanted to sit something on top of the wall, like a roof. Foam would deform differently
than the dirt as they have different Young's moduli and are also made differently (the dirt would be
stamped vs. cut and taped/glued).

This is definitely more of a look and feel and general testing prototype. It answers questions like, 'Will
the bricks stay together, within a margin of error for formation?' and 'Can it do corners?'

I would definitely want an alpha or beta prototype made of that dirt material or a very similar dirt
material, manufactured in a similar fashion, in order to achieve good test results. Multiple bricks , of
course, would be required in order to permit true testing of whether or not they really locked together.

Something that I can't really find out with the manufacturing process that I used for the foam, is if the
dirt would conform to, and stay in the shape given by the stamp, or another manufacturing process.
Also, would the dirt pegs hold against the cross shape if pulled laterally? And, really, would I be able to
make a mold in the developing world that would fit the tolerances of the interlocking bricks, such that
they would fit together. One change I would make already to the prototype is to make the pegs a bit
smaller so that the cross could fit inn, still fairly snuggly, I might make each of them about 2-3 mm
smaller, still putting them flush with the corners of the 'box' such that the space for the cross would be
increased.

Additional problems that might occur with foam models really deal with the manufacturing process.
They simply don't tell me if I would be able to make this brick out of dirt with the same behavior. In this
way, once again, they are more of a look and feel model, and not a complete prototype. It lets people
see the viability of the shape and what it is and isn’t allowed to do, as constrained by its shape.

I would really want some bricks that were made with mold that are very similar to those that are made
in the developing world. I would want to see how packed the dirt was in order to ascertain if the pegs
were going to rip off, and if the corners were sturdy. Due to the relative simplicity of the design I feel
that, stacks of the bricks would hold, as there is little space without material in the end. Also, as I
expressed earlier, I would be very concerned to make sure that the manufacturing process would work
with minimal error and re-pressing. A basic re-design of the molds might be required, allowing the pegs
to be pushed out individually, distributing the pressure over the surface. This would be a movable
stamp part of the mold that would be the inverse of the print. Basically, one end of the mold would be
slide-able after some sort of latch was moved.

However, that said, I would very much like to find out if the pressure from each of the bricks being
distributed differently due to the extrusions and cuts would affect the brick performance. Specifically, I
would want to make sure that the brick wouldn't break in half along the seam between the plus and the
recess (speaking with reference to one side).

One last note on prototypes that would be made before release; I would essentially want to make a
prototype that was as close to the actual ones they would be making on the ground at the site. I would
want to use a similar dirt and binding mix, as well as use molding techniques and molds that are locally
available.

In this way, I could do my best to make sure that the brick would be viable. Also, I would make an entire
prototype house if I could, or at least put weight on a section proportionate to the load it would have to
carry as a section of a house.

Also, if I were to design a new molding system, I would make it such that it would be fast and easy to use,
similar to the charcoal briquette press that Prof. Amy made.

I conclusion, I am very pleased with the outcome of this project and what it allows myself and others to
see about this design. I learned how to deal with multiple axis compatibility (corners) and also how to
deal with inconsistencies in prototypes (the error in the brick width, fixed by the peg squares being
smaller). Also, I learned that over time, with these models, that you learn better manufacturing
processes and the process time on building becomes naturally more quick and efficient (moving to hot
glue and also then figuring out that depressing a hole into the base and component before adhering
them with hot glue). I am very excited to see others’ bricks and if they found different things than I did.
Making it simple was huge too. Apparently, simple design, is a bit difficult.

After doing some basic drawings, I rendered it in solidworks.

Then I rapidly protoyped it.

Perhaps, I went a bit overboard making 4 bricks, but I really wanted to prove the concept to myself and
be able to see the system properties. Also, it never hurts to have a few extra as some might fail during
testing.

Assignment

A rural community makes its own bricks by digging clay from the fields and baking the bricks in

a kiln constructed from field soil. Community members could make brick houses and

schoolrooms inexpensively with this brick if it weren’t for the cost of mortar. They wonder

whether the need for mortar could be eliminated by changing the shape of the bricks so that

they would interlock.

The bricks are molded by pressing the clay into wooden box molds, then

removing it for drying in the sun. Thus the brick pre-form must be

removable without damage. To allow a number of people to mold bricks

at one time, a few dozen molds will be needed, so they should be

simple to make.

Brick walls get most of their stability from

walls that connect perpendicularly at

corners, so the bricks need to be able to

form well-keyed corner joints

Your assignment is to propose a change in the shape of the standard brick (15 x 7.5 x 5cm) to
make it interlocking without mortar. You will need to demonstrate your proposed change by

making prototype bricks that you can assemble in the various ways they would be used in a

structure.
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