I’m looking for some help brainstorming construction methods for making large stackable LEGO(-like) bricks.
Functional - pieces interlock in a similar manner to LEGO
Colored - should be able to color or paint the blocks in various colors. Bonus if waterproof / water resistant.
Size/Mass - Variable - Should be able to easily lifted by one person. A standard 2x2 block should be at least 30cm x 30cm
Variety - Ideally similar to LEGO (e.g., some 1x2, 2x2, 2x4)
Quantity - Looking to make 25-30
Cost - The lower the better. Material costs <$10 / brick would be ideal.
Strength - primarily cosmetic. Ideally able to support several stacked blocks, but doesn’t necessarily need to support someone sitting on it, for example.
In the ballpark:
What I have so far:
Cardboard, either laser-cut or cut by hand using a template. Folded together or hot glued.
Molded from spray foam (probably 2 part to handle interlocking bits?)
Any ideas, however crazy, appreciated !