Required Materials

• Wood sheet 3mm thick
• CAD program (preferably SolidWorks)
• RDWorks software program

Material used

• 1500cm^2 Wood
• 12 min cutting/scanning time

Step 1 - Design using SolidWorks

Feel free to skip and download the finished parts here .

• The Mold

1. Open sketch > select top plane to sketch on.

   Draw polygon and add dimention as seen below.

   
2. Select Featueures > Extrueded Boss/Base.

   On the left change dimension to dessired depth (here 6mm) then press ok.

   
3. Open another sketch > select the face of the part to sketch on.

   Draw polygon and add dimention as seen below.

   
4. Select Featueures > Extrueded Cut.

   On the left change dimension to dessired depth of cut (here 3mm) then press ok.

   

• The Pieces

To make the design of the pieces simpler and custamizable creat a grid first. You can download the grid here .

Now you can draw any pieces you want to using this grid

1. Draw a piece on the grid (make sure it's a closed drawing)

2. Select Featueures > Extrueded Boss/Base.
3. On the left change dimension to dessired depth (here 3mm) then press ok.

Step 2 - Setup for Lazer Machine

Laser Parameter setting

• For Scanning: Max Power is 10%, Min Power is 10%, Speed is 220 mm/s
• For Cutting: Max Power is 70%, Min Power is 70%, Speed is 25 mm/s

The process

1. Save SLDPRT file as dxf/dwg
2. Open Thunder Laser (RDWorks)
3. Import the puzzle pieces and edit the "Cut" parameters to Min Power=70, Max Power=70 , Speed=25

4. Click SaveToUFile button
5. Copy the folder to the USB of the Laser cutting machine and insert it
6. Open file in the display of the machine and copy it to memory
7. Establish your origin and use "frame" button to make sure you have enough space
8. Press Enter

1. After step 3: Import the grid and over lap it with the puzzle pieces by alining them in the upper left corner
2. Select onther color for the grid
3. Right click on the cut option of this layer > change the process to "Scan" and edit parameters to Min Power=10, Max Power=10 , Speed=220

4. Click SaveToUFile button
5. Continue with steps 4 - 8

End result

Mini-Competition Result

🏅Participation Award🏅

• Anas
• Yousry
• Hannah