Interlocking Puzzle Piece Flat

thingiverse

The user aims to create a printable part that replaces the plywood of their CupCakeCNC. To achieve this, they designed interlocking puzzle pieces as a repeating pattern. However, a single layer wouldn't be strong enough, so they added holes for bolted layers, making it stronger. They plan to make corner and edge pieces next, which they think can be laser cut. The current piece size is 40mm x 40mm x 4mm, with a tongue length of 60mm. Holes are 4mm in diameter and spaced 20mm apart. They previously tried 60mm x 60mm x 5mm pieces but faced head crashes due to ABS shrinkage. The infill solidity was set at 1.0, which might have been a factor. The object was designed in Art of Illusion, with objects such as Puzzle_Curve_No_Clearance, Curve 1, and Puzzle_Piece_With_Holes. The final .stl output used Puzzle_Piece_With_Holes, made from a 4-unit extrusion of the mesh and CSG union of four cylinders for drill holes. The .gcode file takes about 16 minutes to print on a CupCakeCNC with a hexagonal fill. To assemble the pieces, simply fit the 'tongues' into the 'mouths,' with no wrong way. For two-layer setups, align the holes of one layer with four separate pieces in the other layer and use M3 nuts, bolts, and optional washers for holding them together. Refer to the pictures for more details.