Design and development of a prototype multi-brick making machine for laboratory and small-scale applications

Traditional brick manufacturing remains constrained by manual processes, resulting in low productivity, high labor costs, and inconsistent product quality. This study presents the design, simulation, and fabrication of a semi-automated multi-brick making machine tailored for laboratory and small-scale applications. The system was conceptualized to enhance production efficiency while promoting sustainable construction practices through the utilization of agricultural and industrial waste materials as feedstock. Critical structural components-specifically the cover plate and molding chamber-were simulated in ANSYS Workbench 2022 under static structural analysis to determine stress distribution, deformation, and safety margins. The results validated the mechanical reliability of the design, prompting the use of 10 mm and 12 mm mild steel plates for fabrication. The prototype demonstrated a production capacity of 180 bricks per hour. Moreover, the machine supports circular economy principles by enabling waste-to-brick conversion, thereby reducing environmental impact and manufacturing costs. Its user-friendly configuration facilitates experimentation, skill training, and micro-enterprise adoption, making it a practical technology for educational laboratories and small-scale brick producers.