Daniel’s Final Project Update

Description / Documentation 

Updated Description:
For my final project, I’m continuing to explore the creation of 3D-printed jigsaw puzzles. During our class on tiling, the idea of designing puzzle pieces caught my interest, and I realized it would be both a challenging and rewarding endeavor. Since I haven’t seen other students tackle a similar project, I believe this work offers a unique perspective on the creative possibilities of 3D printing.

Initially, my main objective was to create a jigsaw puzzle cutter algorithm or script capable of generating puzzle pieces based on customizable parameters, such as piece size and interlocking shapes. However, after nearly a month of development (on and off and jumping in between milestones), I’ve found this approach to be more ambitious than feasible within the project’s timeframe. While my current script successfully defines the size of the cutter (e.g., 300 mm x 250 mm) and separates it into rows and columns, I’ve struggled to implement the “teeth” curves that allow the pieces to interlock properly.

Given these challenges, I’ve pivoted to the alternative or backup plan: creating a set of at least three distinct puzzle cutter designs via computational fabrication and some manual work, which will serve as a backup solution to deliver completed puzzles.

Currently, I have successfully created two distinct jigsaw puzzle cutter designs:

1. Design A: A 203.2 mm x 152.4 mm (8 in x 6 in) puzzle with 7 rows and 5 columns, resulting in 35 pieces. This design represents a flat, traditional jigsaw puzzle with standard interlocking pieces.
2. Design B: A 152.4 mm x 152.4 mm (6 in x 6 in) puzzle with 6 rows and 6 columns, resulting in 36 pieces. This design correlates to a terrain map jigsaw puzzle featuring topographic details.

Below are images of the puzzle cutters in action:

Traditional jigsaw puzzle cutter: Cutting a rectangular box of the same size as the cutter to create the traditional jigsaw puzzle design.

Terrain map puzzle cutter: Cutting a topographical 3D map generated from GEOTiff geographic information system (GIS) data, similar to the process we explored earlier this year.

Due to the closeness of the final project deadline, I will not be able to experiment with multi-color printing or commission professionally colored prints for a more polished aesthetic. However, I will ensure that each puzzle is printed in a different color to visually distinguish them. Additionally, I am designing a yellow jigsaw puzzle holder for each of them to keep the pieces in place, which will provide a clean and organized presentation for the completed puzzles.

Computational Design

The terrain map jigsaw puzzle leverages GeoTIFF data, a technique we explored earlier this year in class. Using QGIS, I imported elevation data from geographic information system (GIS) sources to create a 3D topographic map. The elevation information, encoded as pixel brightness, was processed into a 3D surface in Rhino and Grasshopper using the Human plugin. This workflow involved mapping pixel brightness to z-axis elevation, generating lofted surfaces, and closing the geometry to make it 3D-printable. This approach highlights how computational tools transform raw geographic data into tangible, functional designs. (the beige puzzle)

For the jigsaw puzzle cutters, computational design was employed to automate the creation of the puzzle templates. A script was developed to define the cutter’s dimensions (e.g., 300 mm x 250 mm) and split the surface into rows and columns, effectively establishing the grid structure for the puzzle pieces. While the script currently lacks the functionality to generate interlocking “teeth” curves, I used Rhino’s Interpolate Curve tool to manually draw these details. Each tooth shape was carefully designed for seamless interlocking between rows and columns, and the perimeter was enclosed with a square or rectangular frame. Finally, the curves were joined, extruded into a solid cutter, and used with Boolean Split to cut the puzzle pieces from the base geometry.

By combining algorithmic tools, manual refinement, and advanced software, computational design enables the seamless integration of data processing, parametric modeling, and fabrication, bringing these innovative jigsaw puzzles to life.

Timeline

October 31 – November 18:

• Research Phase: (Finished)
  Research existing jigsaw puzzle cutter algorithms and analyze their structures. Focus on understanding algorithmic parameters that define piece shapes, such as interlocking mechanisms and edge randomness.
  Study the mechanics of puzzle cutting to identify feasible methods for 3D printing.
• Design Drafting: (Finished)
  Develop initial sketches or digital drafts for the puzzle cutter, exploring different piece shapes and edge designs.
  Experiment with parameter settings for the algorithm, aiming to generate unique yet interlocking puzzle pieces.
• Algorithm and Prototype Development: (In Progress)
  Begin writing or refining the puzzle cutter algorithm if applicable. Ensure that the algorithm can modify piece shapes based on input parameters (e.g., piece count, shape complexity).
  Alternatively, finalize at least three distinct puzzle cutter designs that can be used for testing.
• Testing Phase: (In Progress – 2 Completed, 1 Remaining)
  Create digital simulations or early 3D prints of the cutter designs to assess their accuracy and fit.
  Make adjustments as needed, documenting the changes and their impact on the puzzle’s overall cohesion.

November 19 – December 2:

• Puzzle Design and Printing: (In Progress – 1 Fully Completed, 1 Printing, 1 Remaining)
  Finalize puzzle designs based on the selected designs. Ensure a diverse range of shapes to meet the project’s creativity goals.
• 3D Printing and Evaluation: (In Progress – 1 Fully Completed, 1 Printing, 1 Remaining)
  Begin and finish 3D printing at least three complete puzzles using finalized cutter designs or algorithm outputs.

Deliverables

1. Three distinct jigsaw puzzle cutter designs:
   • Flat, traditional jigsaw puzzle:
     • A 203.2 mm x 152.4 mm (8 in x 6 in) puzzle with 7 rows and 5 columns, resulting in 35 pieces. This design features standard interlocking pieces. (Green)
   • Terrain map puzzle:
     • A 152.4 mm x 152.4 mm (6 in x 6 in) puzzle with 6 rows and 6 columns, resulting in 36 pieces. This design features topographic details for a terrain-like aesthetic. (Beige)
   • Dimensional puzzle:
     • A puzzle design with varying z-height to introduce a 3D element, adding complexity to the assembly.
2. A partially completed puzzle cutter algorithm:
   • The algorithm defines the cutter’s size and structure (e.g., rows and columns), but the interlocking “teeth” remain incomplete.
3. Design and 3D printing of three puzzles, with the following details:
   • Each puzzle will be printed in a different color to visually distinguish them.
   • A yellow puzzle holder will be printed for each puzzle, designed to organize and secure the pieces in place.