Nazmul Azim Khan is a second-year student majoring in computer design at New South Wales University. In his latest digital design project, he was tasked with creating a conceptual panel made from acrylic plastic that could be assembled using a spider joint system. This innovative approach not only challenged his technical skills but also pushed the boundaries of traditional construction methods.
The spider joint system is an external structural framework that connects glass panels using bolts. What makes this project unique is the complexity of the spider joints—each one has at least 15 legs. However, thanks to 3D printing technology, such intricate designs become feasible and efficient. This technology allowed Khan to experiment with different configurations without the limitations of conventional manufacturing.
Khan used Rhinoceros software along with its plug-in, Grasshopper, to generate scripts for the spider joints. Grasshopper is a visual programming tool that lets users "draw" models while simultaneously writing code. This made it easier for him to visualize and adjust the design in real-time. According to him, the most challenging part wasn’t the coding—it was the actual design process, which required careful consideration of geometry, load distribution, and aesthetics.
A large-scale image of the model is displayed below, showcasing the intricate details of the spider joints and the overall structure.
“The hardest part of the design was figuring out how the spider joints would connect to the panel,†Khan explains. “I wanted a clean, seamless look without visible nuts or bolts. So I went with screws and expansion bolts. The idea is to insert the expansion bolt into the 3D-printed spider joint, then screw it in place, so nothing is exposed.â€
The current design spans 10 x 10 meters, but due to its parametric nature, it can be easily adapted to fit various spaces. By adjusting parameters like panel size and curvature, the spider joint model updates automatically. The only non-3D-printed component in the entire assembly is the screw.
Khan’s team has already started working on the next phase of the project, aiming to create a full-scale installation of the digital model as a real architectural structure. “We’ve already secured a booth space, and our plan is to modify the panel’s dimensions and shape next month to fit the exhibition area,†he says.
Another image of the design is shown below, highlighting the evolution of the concept.
Using digital modeling tools, Khan was able to quickly test and refine the spider joints and truss systems. One key decision was to reinforce the spider joints with a truss system inspired by complex bridges, such as the Sydney Harbour Bridge. While the original design was based on straight lines and rectangles, introducing curves and rotating truss elements added a dynamic, fluid quality to the structure. This balance between form and function made the design visually striking and structurally sound.
The ability to rapidly produce physical models gave the team confidence in the final assembly. Khan emphasizes the importance of 3D printing throughout the process: “The performance of the spider joints met our expectations, which was a big relief. Assembling such precise components under a 1mm tolerance is risky. To avoid errors, we printed multiple prototypes and tested them to ensure they fit perfectly and were strong enough.â€
This project not only showcases the potential of 3D printing in architectural design but also highlights the power of digital tools in transforming abstract ideas into real-world structures. With continued refinement and testing, Khan and his team are confident that their design will make a bold statement in the world of modern architecture.
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