Brick It
Overview
Built “Brick It”, autonomous LEGO 3D brick printer for 16×16 mosaics and 3D voxels. Delivered repeatable, accurate placement with fast throughput and quick changeover. Generated EV3-ready toolpaths from images/STLs for end-to-end autonomous builds. Support multi-color prints via LEGO color mapping and quick-swap magazine. Provide documented test procedures and run logging for engineering reviews. Developed a proprietary slicer web app to convert 2D and 3D models to compatible Lego voxels.
Results
Modelled full mechanism in SOLIDWORKS with GD&T, ran FEA on subframes for stiffness and weight trade-offs. Designed a quick-change magazine and feed system; iterated with 3D-printed prototypes and laser-cut parts. Parameterized grid size, color palettes, and placement rules in code. Developed a React/Three.js slicer generating EV3-compatible toolpaths (.txt) with LEGO brick color mapping and travel-minimizing sorting. Implemented motion control with jerk limits, jam detection, and retry logic in RobotC program. Achieved 9.5 s/brick average cycle time across 25+ builds. Demonstrated successful end-to-end autonomous builds with zero operator touches during runs. Reached up to 92% multi-axis placement accuracy in validation runs. Cut end-effector deflection by 15%, improving stability at speed. Reduced part count by 30% and changeover time by 25% using a quick-change magazine interface. Drove manual slicer edits to near-zero after validation stable EV3 toolpaths. Enabled future scalability to accomodate more magazines and colors.
