Many complex natural and artificial systems are composed of large numbers of elementary building blocks, such as organisms made of many biological cells or processors made of many electronic transistors. This modular substrate is essential to the evolution of biological and technological complexity, but has been difficult to replicate for mechanical systems. This study seeks to answer if layered assembly can engender exponential gains in the speed and efficacy of block or cell-based manufacturing processes. A key challenge is how to deterministically assemble large numbers of small building blocks in a scalable manner. Here, we describe two new layered assembly principles that allow assembly faster than linear time, integrating n modules in O(n2/3) and O(n1/3) time: one process uses a novel opto-capillary effect to selectively deposit entire layers of building blocks at a time, and a second process jets building block rows in rapid succession. We demonstrate the fabrication of multi-component structures out of up to 20 000 millimetre scale spherical building blocks in 3 h. While these building blocks and structures are still simple, we suggest that scalable layered assembly approaches, combined with a growing repertoire of standardized passive and active building blocks could help bridge the meso-scale assembly gap, and open the door to the fabrication of increasingly complex, adaptive and recyclable systems.
Keywords: digital fabrication; layered assembly; multi-material printing; self-alignment; self-assembly; voxel printing.