Puzzle Ball – Toy Redesign

A simple and very old puzzle ball  which consist in 6 nearly similar modules that fit together by form.

This exercise was to understand each shape and rebuild the toy using different technology than the original, which is injection molding ( in this case, ABS).

3d measurement of the puzzle
Puzzle Ball assembled and modules
Puzzle Ball detail of assembling
detail of assembly

once done with the modeling of the original product I started with the conversion of each module to serial planes


Then,  the 2D files with tolerances for the laser cutter

The nesting was made based on the scrap material I had.

laser cutter file

Cutting the pieces

The cutter provider is Xyzero

final toy -
Final toy -132 pieces