during this year’s NYCxDESIGN, a tricolored pavilion woven of red, white and blue plastic mesh popped up in times square. looking closely, the colorful walls of the installation are in fact not ‘walls’ at all, but have been created with a futuristic plastic chainmail-like fabric that goes by the name of kaynemaile.


the mesh — made from a recyclable polycarbonate — has been created by lord of the rings set designer kayne horsham, who became rather practiced in the art of designing and creating chainmail during his work on the fantasy trilogy for which he wove millions of rings into armor robes for viggo morteson and orlando bloom alike. the patented plastic mesh is already being used by architects to create, divide and protect building interiors and exteriors around the world.



after hours spent hand assembling chainmail suits during his lord of the rings career, horsham came to the idea that there must be an easier was to create fabrics of a similar structure without interlinking each loop by hand. to produce kaynemaile — which was awarded best architectural product at the NYCxDESIGN award — horsham experimented to produce a seamless plastic mesh via an injection moulding process, eventually creating a 3D material made up of solid rings with no joints or seems. this means that kaynemaile can be produced in unlimited sizes, using a wide range of colors. the fabric itself is made from a recyclable, UV stabilized high-spec polycarbonate, which is resistant to fire and almost impossible to damage.



the mesh is already being used widely around the world, forming dividing screens in a new zealand airport, walls in aukland university campus, and a carpark facade in australia. just as apt for interiors as exteriors, the material works as an effective wind and rain screen due to its cross-sectional density. with two layers of mesh, weather penetration is lowered to just 5 per cent. the architectural armour is also apt to keeping out the sun, letting you control the level of light entering a building down to 75 percent. in fact, it’s not all that surprising that kaynemaile is so strong, since the mesh is made from the same material as astronaut helmets.



besides being recyclable, the material ranks highly on the eco-scale, since it takes just 1/8th of the energy needed to create metal chainmail.  the lightweight plastic mesh is expected to stay strong for a full 20 years, and won’t melt or go brittle in adverse weather conditions. where metals might corrode or oxidise, kaynemaile holds true to its tensile strength. stronger and lighter than glass, the fabric weighs just 3 KG per square meter, making it a perfect choice where a low static load on building is required. ‘kaynemaile is the link between art and science’ explains horsham.

    have something to add? share your thoughts in our comments section below.

    comments policy
    LOG IN
    designboom's comment policy guidelines
    generally speaking, if we publish something, it's because we're genuinely interested in the subject. we hope you'll share this interest and if you know even more about it, please share! our goal in the discussion threads is to have good conversation and we prefer constructive opinions. we and our readers have fun with entertaining ones. designboom welcomes alerts about typos, incorrect names, and the like.
    the correction is at the discretion of the post editor and may not happen immediately.

    what if you disagree with what we or another commenter has to say?
    let's hear it! but please understand that offensive, inappropriate, or just plain annoying comments may be deleted or shortened.

    - please do not make racist, sexist, anti-semitic, homophobic or otherwise offensive comments.
    - please don't personally insult the writers or your fellow commenters.
    - please avoid using offensive words, replacing a few letters with asterisks is not a valid workaround.
    - please don't include your website or e-mail address in your comments for the purpose of self-promotion.
    - please respect jury verdicts and do not discuss offensively on the competition results
    (there is only one fist prize, and designboom usually asks renown professionals to help us to promote talent.
    in addition to the awarded designs, we do feel that almost all deserve our attention, that is why we publish
    the best 100-200 entries too.)

    a link is allowed in comments as long as they add value in the form of information, images, humor, etc. (links to the front page of your personal blog or website are not okay). unwelcome links (to commercial products or services of others, offensive material etc. ) will be redacted. and, ... yes, spam gets banned. no, we do not post fake comments.


    a diverse digital database that acts as a valuable guide in gaining insight and information about a product directly from the manufacturer, and serves as a rich reference point in developing a project or scheme.

    technology news