Benjamin Wand - Verbose CV

Dovetail printable large craft(s)

Summer 2023

The project

I wrote a first prototype for the project of Kerry Williams from Alaska who would like to build large objects, like kayaks, from 3d printed puzzle pieces, so, now that more and more people have access to 3d printers, more people have the chance to build large things on their own.
The first prototype is a sphere shaped puzzle that I wrote in OpenSCAD and the pieces are hexagons and pentagons, like a soccer ball / truncated icosahedron. The files are on GitHub and on Printables.

I went for a truncated icosahedron because

The maths of the truncated icosahedron is taken from this printable.

As you can see on the image with the blue ball, the pieces have an edge inside in order to ease the maneuvering of the pieces against each other and to keep the last piece from falling inside of the ball.

The tilted dovetail is something I haven't seen before, so maybe I've invented it.

tilted dovetail sketch
blue sphere puzzle
photo: Kerry Williams

The code

Apart from moving around pentagons and hexagons, the code does this: call one piece, and cut away the previous pieces. This way it is made sure that the pieces fit neatly into each other.

The data for each piece looks like that:

 rotate([hh,0,120]) rotate([hh,0,60])
  piece(6, 18, [0, 0, 1, 1, 1, 0], $gap); 

and the [0, 0, 1, 1, 1, 0] part encodes which sides are dovetailed or initially flat.
The dovetailed pieces 'bite' into the flat peaces, resulting in two pieces that fit together.

 for (i = interval) { // interval = which pieces
  intersection(){
    globe();         // the sphere
    difference(){
      let($gap = 0) children(i);
      if (i > 0) for (k = [0:i-1])
        let($gap = gap) children(k);
    };
  };
}; 

The $gap makes sure that the pieces can get disassembled again.

display how puzzle pieces 'bite' into each other

Text last updated: April 29th 2024