For this assignment, our team was tasked with producing snug-fitting nervous system puzzles using no adhesives. We aimed to understand and apply design principles for laser cutting, and post-process the wooden puzzle with a clean geometry and minimal charring.
We utilized Draradech’s puzzle-making algorithm, which generates SVG files. For our first cut, we used the following parameters as a puzzle template:
- Seed: 3604
- Tab Size: 27%
- Jitter: 5%
- Diameter: 240mm
- Rings: 8
- Circle Warp: Enabled
- Truncate Edge Pieces: Enabled
Image 1: SVG file generated for puzzle
After obtaining the template, we used Adobe Illustrator to incorporate three unique “noun” pieces to the puzzle. We used SVGs of the following objects:
- Microscope: as a nod to the MBE program.
- Skateboard: because one of our team mates is a pro-skater.
- Mate: because one of our team mates is Argentine, and it’s a traditional beverage.
We employed the shaper tool from Adobe Illustrator to cut the overlaps between the “noun” pieces and the puzzle template, and then we used the scissor tool and curvature tool to ensure the geometry of the puzzle was still functional.
Image 2: Puzzle template for laser cutting
Lastly, we modified the line width to be 0.072pts, and resized into an 8.5″x8.5″, in order to be correctly inputted to the laser cutter.
Image 3: Line width modified to 0.072
We used the Epilog Pro Laser Cutter to cut the wooden piece, using the following settings:
- Speed: 55s,
- Power: 30
- Frequency: 50
- Cycles: 4
Image 4: Epilog Pro laser cutting the wooden piece
The resulting cut didn’t go all the way through the wood, causing the pieces to break off when we tried to disassemble the puzzle.
Image 5: Wooden piece not being laser cut correctly
We tried adding more cycles (6 total), but even when that helped, we discovered that our pieces were so small, that they were breaking off anyway. We therefore decided to redo our puzzle, and reduce the puzzle rings from 8 to 6 on the puzzle template generator.
Image 6: Final puzzle SVG file
Finally, we wanted to incorporate a print on the surface of the puzzle to make it more similar to actual jigsaw puzzles. We wanted to use a picture of Rice University’s campus, so we printed it out on a piece of paper, and the glued it onto our wooden piece prior to laser cutting with a spray adhesive.
Image 7: Spray adhesive
The final cut was performed correctly, with some charring, especially on the longer, “noun”-piece edges, but worked correctly as a jigsaw puzzle, with unusually shaped pieces.
Image 8: Final jigsaw puzzle
This project provided hands-on experience with the complete digital fabrication workflow, from generative design to laser cutting and post-processing. The experience deepened our understanding of how computational designs translate into precise physical components. The final puzzle demonstrates both the technical rigor and creative intent required to produce a clean, well-fitting, and visually cohesive manufactured piece.
Cost Analysis:
| Cost Type | Cost | Price | Source | Quantity | Total |
| Materials | 11″x17″ tabloid printer paper | $0.04/page | Amazon | 1 page | $0.04 |
| Ink | $0.27/page | Amazon | 1 page | $0.27 | |
| Spray adhesive | $0.05/sqrft | Amazon | 11″x17″ | $0.07 | |
| Balsa plywood | $2.66/piece | Amazon | 12″x12″x1/8″ | $2.66 | |
| Labor | Puzzle designer | $24.48/h | Zip Recruiter | 4hrs | $97.92 |
| Machining | Electricity | 0.5kW/h
$0.1405/kWh |
Accurl | 1.5hrs | $0.11 |
| Total | $101.07 | ||||
Image 9: Clean workstation