Brick It - Autonomous LEGO® 3D Printer
What?
• Build an autonomous LEGO EV3 brick-placement system with end-to-end runs • Design the full mechanism including a quick-change magazine and feed system • Provide a software toolchain (React/Three.js slicer) that outputs EV3-compatible toolpaths (.txt) with color mapping • Implement motion control in RobotC with reliability features (jerk limits, jam handling, retry) • Keep the system scalable by parameterizing grid size, color palettes, and placement rules
How?
• Model the complete mechanism in SOLIDWORKS with GD&T and run FEA on subframes to balance stiffness and weight • Prototype rapidly with 3D-printed and laser-cut parts, iterating tolerances and feed geometry • Build a slicer that maps brick colors and sorts moves to minimize travel before exporting toolpaths • Program motion control with jerk limits, jam detection via sensors, and automatic retry logic in RobotC • Engineer a quick-change magazine interface and stiffen the end-effector to control deflection at speed
Results
• 9.5 s per brick average cycle time across 25+ builds • Zero operator touches during runs for true end-to-end autonomy • Up to 92% multi-axis placement accuracy with 15% lower end-effector deflection • 30% fewer parts and 25% faster changeovers enabled by the quick-change magazine • Stable EV3 toolpaths that drove manual slicer edits to near-zero and allow future expansion to more magazines and colors
Link to our custom slicer: https://brickit.netlify.app/
2025
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