Manufacturing-ready

Plastic Block Modular Wall

Introduction

A coordinated family of plastic bricks that brings visual variation, modular assembly and manufacturing intent into one system.

Details

Type: Product design case study
Status: Ready for injection molding
Software: SolidWorks · KeyShot

Project & visuals: MayCo.

Modular plastic block system

Three brick variants. One shared assembly principle.

A modular wall system ready for injection molding.

Plastic Block Modular Wall — Assembled wall and alternate brick designs — 01 Assembled wall and alternate brick designs

01 / The design challenge

The wall begins with the connection.

The brief combined two goals: make the wall modular and prepare the blocks for molding. The joint was central to both the assembly logic and the way the bricks work together.

Plastic Block Modular Wall — Locating features (1) and edge connection (2) — 02 Locating features (1) and edge connection (2)

01 · Locating featuresRaised features at the top define how adjacent rows meet.
02 · Edge connectionThe side detail forms part of the block-to-block interface.

The connection geometry was designed to resist leaning perpendicular to the wall plane, in both directions. This focus on the joint gives all three brick variants a consistent assembly principle, even as their visible designs change.

02 / Part development

Designed from the inside out.

The visible face is only part of the design. Section renderings reveal the internal ribs, perimeter frame and connection geometry behind the finished block.

Plastic Block Modular Wall — A / Local connection detail — 03 A / Local connection detail

Plastic Block Modular Wall — B / Repeated wall section — 04 B / Repeated wall section

A / Local connection detailA section view exposes the locating features and the ribbed geometry around the central opening.
B / Repeated wall sectionThe same internal design continues through a row of assembled blocks.

Design development: The project brings the outer form and internal part geometry together as one molding-ready system. The blocks are ready for injection molding.
Software: SolidWorks · KeyShot — CAD development and product visualization

03 / The outcome

Three designs. One modular system.

A family of three plastic bricks with different visual expressions and one shared assembly principle. The outcome connects the individual part, the wall and the intended manufacturing process.

A coordinated familyThree brick designs, developed to work together.
A consistent interfaceOne assembly principle across the variants.
Ready for injection moldingA block design ready for injection molding.