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3D Jigsaw Puzzle

PostPosted: Sun Nov 04, 2018 4:15 pm
by George B.
I would like thank Edward Powell at Vectric for his inspiration and presentation about 3D jigsaw puzzle making at the User Group Meeting 2018. The picture below shows I was successful. I also created a written procedure which may help others also create a puzzle and will help me remember what to do in the future when trying to repeat the process.
George

Re: 3D Jigsaw Puzzle

PostPosted: Mon Nov 05, 2018 12:56 am
by highpockets
Nice work George. Thanks for sharing the procedures. Wish I could have made the conference.

Re: 3D Jigsaw Puzzle

PostPosted: Mon Nov 05, 2018 2:58 am
by mtylerfl
Very nice! Glad to see someone using the technique Edward showed us!

Re: 3D Jigsaw Puzzle

PostPosted: Mon Nov 05, 2018 7:33 am
by LittleGreyMan
Thanks for sharing, George.

Re: 3D Jigsaw Puzzle

PostPosted: Mon Nov 05, 2018 11:25 am
by martin54
Nicely done George, I made one but didn't post it on here because it was made using a user group meeting tutorial :lol: :lol:

Re: 3D Jigsaw Puzzle

PostPosted: Tue Nov 06, 2018 6:57 pm
by RebeccaJ
Very Cool, Nice to see you have made use of this cool technique! Thanks for Sharing!

Re: 3D Jigsaw Puzzle

PostPosted: Sat Nov 10, 2018 2:54 pm
by Roger Gaborski
Looks great George
Roger

Re: 3D Jigsaw Puzzle

PostPosted: Wed Dec 26, 2018 6:46 am
by nurb
Here's another example of a puzzle using the technique illustrated at the Chicago User Group 2018.

The puzzle was created as a Christmas gift for a relative. It consists of 176 pieces and was made from a variety of cherry and maple pieces. All puzzle pieces were cut with a 1/8" 2 flute up-cut endmill. To allow proper fit of the pieces, the allowance between pieces was set to -0.005". The graphics were V-carved with a 30 deg V-bit and 0.10" max depth. Coloring was done with spray-on and hand-applied ink followed by a poly clear coat.

Lessons learned:
1)
Next time I'll use a down cut endmill. An up-cut endmill was used to clear the flat areas during V-carving. But, it has a tendency to pull the small puzzle pieces from the table. This led to lesson 2.
2)
Because the up-cut endmill had a tendency to pull the pieces up, I had to resort to carpet tape with aggressive adhesive. The downside was it took a very very long time to remove the adhesive from all 176 pieces. :cry: Next time, if a do a project with this many tiny pieces, I'll fabricate a vacuum hold down.

Re: 3D Jigsaw Puzzle

PostPosted: Wed Dec 26, 2018 1:28 pm
by martin54
nurb

Now that is impressive :lol: :lol:
What is the overal size & how easy was it to put the pieces together after cutting before you carved it? I did one after the UK user group meeting but it's only 9 pieces, just did a simple one for my Grand Daugher :lol: :lol:

Re: 3D Jigsaw Puzzle

PostPosted: Wed Dec 26, 2018 3:57 pm
by nurb
The overall size is 24"x16". The pieces actually fit together quite nicely and the puzzle maintained its "squareness" even when fully assembled. I attribute it to two things:

1)
Before starting, I made sure the CNC table was perfectly square and trammed the spindle to ensure the pieces slid together with no off-angles.
2)
I dialed in the allowance offset between the pieces with some trial runs before settling on -0.005". It was actually set looser at -0.008" to begin with but there was too much slop and the pieces were too loose when assembled.

Re: 3D Jigsaw Puzzle

PostPosted: Sun Dec 30, 2018 4:14 pm
by martin54
The overall size is 24"x16". The pieces actually fit together quite nicely and the puzzle maintained its "squareness" even when fully assembled. I attribute it to two things:

Haha, I wasn't refering to the fit, t was the thought of all those bits on the table with absolutely no clues as to how it all went together :lol: :lol:
I only had 9 pieces so 4 corners only left me with 5 bits & only one with no straight edge :lol: :lol:

I did the same thing, ran a couple of pieces as a test fit although I allowed a bit of slop in mine, didn't want it to be to tight a fit with it being for a 3 year old :lol: :lol: