A puzzle game composed by a dozen of 3D tiles can be printed to reach a remarkable size, and it will be a very appreciated present. If Easter is coming you can also decide to make an egg shape instead of the classical cube.
Step 1: The basic shapes
Draw a cube with the right dimensions, or an egg applying the revolve command to a simple curve. Since I'm not skilled enough to teach advanced modeling in Rhino, I will use basic commands which are easily found in main toolbar or menu list of the software.
Step 2: The power of parameters
You can analyze the schematic to see which commands are used and how they are connected. I added a few notes over the images, so that you can find out the full name of each function.
Step 3: The subdivisions
Probably there is a faster way to subtract spheres from solids and to join them to other tiles in Grasshopper, but I couldn't find it, so I had to do that in Rhino. So, after baking both Voronoi solid and spheres group, turn off the Grasshopper plugin and go working on Rhino window.
Step 4: The choise
Now you can proceed in different ways. I decided to hide one tile at a time, the I deleted the unwanted spheres and hid the spheres I decided to keep. Go on in this way until nothing is shown. Then unhide everything.
Step 5: Fusion
Step 6: Subtract
Step 7: The joints
Try to not protrude spheres all around the same tile, because it would simplify the game too much.
Step 8: The egg
I found some problem in setting the points inside the egg, anyway I made a Boolean Intersection between each tile and the egg. Now I have to choose the spheres in the same way I used for the cube.
Step 9: Blending
Step 10: Time to play
Now you only have to save the pieces in one or more .stl file (it's in the export options of Rhino) and send it to the 3D printer.
There is a "nota bene" to add: there are some chances that the puzzle will not work.
This could be due to two causes: first the rigidity of the printed piece and material, among with the percentage of filling chosen in printing settings. Second the reciprocal disposal of the tiles' faces. Indeed, since some tiles will certainly be blocked by the others, I'm not sure that every tile will be able to be inserted.
Of course the bigger is the number of tiles, the harder will be inserting them... you only have to try.
Step 11: Enjoy with colours
I hope you will be able to model your own puzzle, since I still have to set up the STL files, but I will attach them in next weeks.