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Stackaponics

Cornell University, AAP
DESIGN 6152: Design and Making II
3D Printing PLA, Capillary Wicks, Chia Seedlings
Spring 2025

Description

A parametric and modular hydroponic kit for the at-home market that uses capillary irrigation to draw water from its surroundings and grow microgreens—a domestic product reimagined as a bio-hybrid design object.

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Design Methodology

Stackaponics addresses the growing need for sustainable home gardening in urban environments where space and resources are limited. Drawing from research showing that hydroponic systems can reduce water use by up to 95% and increase yields by 30–50% compared to soil-based methods, the project explores alternatives to traditional hydroponics, which often depend on pumps and sensors that increase cost and maintenance. Instead, Stackaponics focuses on passive irrigation through capillary action, creating an easy-to-use kit for growing microgreens such as chia seeds. Developed as part of the course DESIGN 6152: Design & Making Across Disciplines II, the project takes inspiration from low-cost hydroponic systems and 3D-printed units with built-in perforations. It explores how geometry can optimize water flow and plant support, aiming to make gardening accessible without requiring daily upkeep.

The project began with interviews with botany and horticultural industry experts, which highlighted the demand for low-maintenance, space-efficient designs. These insights informed an open-ended parametric design exploration in Rhino and Grasshopper to generate stackable forms. Early sketches evolved into digital models that were tested for stability and water flow, followed by four iterations of 3D-printed prototypes incorporating perforations, expanded surface areas, and add-ons such as leaflets with capillary wicking ropes. Feedback from simulations and physical trials refined the dual-part structure—consisting of a core body and modular extensions—while growth tests using chia seeds validated hydration performance and plant viability. This iterative cycle, blending computational design with hands-on fabrication, ensured the system balanced functional performance with ease of assembly.

The project employed a two-part methodology that fused geometric design and water behavior. Parametric modeling in Rhino and Grasshopper used variables such as height, curvature, and tessellation to generate lofted, stackable units, while remaining constrained by the requirements of 3D printing. Prototypes were fabricated using a Creality Ender 3 SE with PETG filament, then tested for stacking stability and perforation effectiveness in supporting hydration and seed retention. Water behavior was studied through Kangaroo2 and Blender fluid simulations to analyze surface flow, alongside capillary tests using nylon ropes that achieved full saturation in approximately three to five minutes. Manual pour tests further confirmed water directionality and distribution. Growth trials involved applying chia seed paste to evaluate germination, root integration, and overall plant health, helping identify which geometric parameters most strongly supported growth.

Looking ahead, Stackaponics could expand as an open-source system, allowing users to customize modules for different plant types or scales. Future iterations may integrate nutrients directly into the structure to support longer-term growth, while maintaining the simplicity of the passive system. With low production costs, the project shows strong potential for the at-home gardening market, and additional features such as embedded monitoring could be introduced without compromising accessibility. Over time, as plant roots intertwine with the printed structure, the system evolves into a bio-hybrid object—promoting sustainable urban gardening while blurring the boundary between designed artifacts and living systems in pursuit of a broader ecological symbiosis.

Thomas Knoepffler

Design + TechNOLOGY