Adaptive Recycled Plastic Chainmail Structures

Adaptive Recycled Plastic Chainmail Structures

Research and Development

• The 2025 study titled “Adaptive recycled plastic architecture: Vacuum-Sealed Chainmail Structures Through Computational Design” aims to develop “vacuum-sealed chainmail structures” using recycled plastic filaments. This system is optimized for lightness, flexibility, and structural performance. (ResearchGate, arXiv, NYU Urban Lab)

• The research explored three types of geometries (triangular, circular, rectangular). Results showed that the rectangular chainmail configuration provided the most efficient deformation capacity and load-bearing performance. (arXiv)

• Through vacuum sealing, the rigidity (stiffness) of plastic structural elements can be increased, making them more resistant to forces such as wind, snow, and loads. (NYU Urban Lab)

• Plastics are interlocked in modular form without chemical bonding, which allows each module to be re-melted and reused. This approach represents a true circular economy model for architectural applications. (NYU Urban Lab)

Scaling Up Studies

• The article “Chain mail structures in architecture: a systematic, multi-scalar design exploration” systematically investigates chainmail structures at the architectural scale. It addresses the challenges of scaling from small models (1:10) to larger prototypes, discussing production details of the modules. (SpringerLink)

• This study covers production techniques, structural behavior, connection details, and scaling strategies. For instance, the processes of producing 1:2 and 1:1 scale prototypes are also analyzed. (SpringerLink)

Applications & Industrial Examples

• The company Kaynemaile has reinterpreted the ancient concept of chainmail into architectural mesh surfaces. It provides lightweight and permeable structural elements for applications such as façades, roofing, and interior partitions. (Architizer, Designboom)

• Recently, Kaynemaile developed RE/8 Bio-circular Architectural Mesh, a carbon-neutral material made from bio-sourced polycarbonate. These mesh systems provide solar shading, airflow, and visual transparency. (Architizer, Kaynemaile Architectural Mesh)

• Kaynemaile mesh stands out in projects for its lightweight properties, air permeability, aesthetic appeal, and minimal contribution to structural loads. (Architizer, Designboom)

Architectural and Design Implications

This approach introduces several potential advantages and considerations for architectural design:

  • Lightweight and flexible structures: Plastic chainmail modules are more suitable for façades, canopies, shading elements, temporary roofs, or interior partitions rather than heavy load-bearing structures.
  • Modular and reconfigurable: Modules can be joined, detached, and rearranged, allowing adaptability in design.
  • Circular use: Since connections do not involve chemical adhesives, modules can be remelted and reused, supporting sustainable design.
  • Structural stability and rigidity: Vacuum sealing enhances stiffness, but at large scales, module connections, load distribution, and deformation management become critical.
  • Material behavior and variability: The mechanical performance of recycled plastics can be inconsistent, requiring designers and engineers to carefully set tolerance levels.