3D Puzzle: Wooden Toy Plane for Kids

It's been a while since my last post. I was mainly focused on my job-changes and have been pretty active with volunteering in my interest group at Bitcrafts. Oh yes back to the Instructables. Just last month, I had an opportunity to work with our local laser-cutter developer, Lionsforge, on their Project "Little Hands, Big Heart". In this project, I am tasked to turn a child's drawing into a functional toy. You see, this particular boy likes airplanes and puzzles.

As usual, I had to do something epic. :)

In this Instructables, I will walk through my process on designing this toy. Hope you liked it.

All software used to design the puzzle are freely available to the public.

Let's take flight!

• 3mm MDF Boards
• Lasercutter (>40W)
• 3D CAD Software (Onshape; In my case)
• 3D Spatial Awareness
• Some mechanical intuition

The first step was to form an imagery of the end goal I have in mind. To do this, I approached our trusty Google Images. Basically, I have this end goal of a airplane that comes out of the 90s Toy Story. Something that is relatively sizable to a kid but yet have some form of nostalgia of an old wooden airplane toy. I am not an experts of planes but the bi-planes in the 19th Century seemed very retro and fitting.

For sizing, I am targeting those shown in the images. A design with a relatively teardrop-shaped fuselage.

In terms of the final toy designing approach, I take reference of the ancient but trusty laser-cutting technique of slots like the one shown in the toys of U-Gears.

Referenced Images Assets:

https://assets.skiesmag.com/wp-content/uploads/2021/03/1936-Stearman-Gilmore-mitch-bowers-1.jpg

https://m.media-amazon.com/images/I/6129EueAgiL._AC_SX679_.jpg

https://m.media-amazon.com/images/I/719qpRZnLzL._AC_SX679_.jpg

For 3D modelling, I used Onshape as a means to create the 3D models. Onshape is free for use (but take note, your files will be public). For mine, I am using a Educator's version. Feel free to use any type of 3D modelling software of your choice. It'll help a lot if you are using a platform that you are very comfortable with.

Our end goal is to create a 2D to 3D design. Why? Because it can be made by a lasercutter and secondly, it's cool to see 2D pieces forming into a 3D object! That's the spirit of IKEA isn't it?

To start off, know your constraints. Here's some that come to my mind during designing:

• Your layers have to be limited to the thickness of the stock (i.e. 3mm)
• You need to account for manufacturing variations
• You need to consider how the parts come together

Next, I follow these steps:

1. Start with a 3D shape of the plane
2. Imagine how many sheets of 3mm can fit into that shape and space accordingly
3. Start with 1 dimensions across (e.g. X-axis)
4. Then with another dimensions vertically (e.g. Y-axis)
5. Split/Trim/Boolean the parts from (1) using planes or sketches (depending on your proficiency level) to create 3mm slices of the 3D models.

It's ok if you feel that this is a bit challenging. What you can do is to try doing that on a cube first. Practice, then try the exact same approach on a more complicated geometry. Trust me, it works!

Tips: After completing creating slices, you may use offset tool to move faces to allow 0.2-0.3mm of gap between the pieces so that fitting could be easier during assembly. Why? This is because during laser cutting, you beam is not entirely straight so it tapers. This causes either a diverging or converging taper, depending on your focal length.

Referenced Images Assets:

https://m.media-amazon.com/images/I/719qpRZnLzL._AC_SX679_.jpg

After completing the 3D model, you should be confident of your design. Just check through to ensure that all in Step (2) is covered. The next step is to export the files as .dxf. This is the file format that allows you to export into vector files that will then feed into your lasercutter. If you have difficulty doing this, you can ask your local lasercutting shop to assist.

I do run a lasercutting service in Singapore, Planarworks. You may reach out to me if you have any questions, I would be happy to support if I am available.

After some session of "piu-piu", you get your parts!

Feel free to drop down a comment, if you think this is meaningful! If you wish to have the plans, I might be releasing them after some refinements to the tolerances.

I have attached a .pdf on how the parts go together. Hopefully, it can inspire some of you.

There's a learning curve in designing slotted designs like toys in U-Gears, it just needs some practice and you will grasp the intuition of it.

And with that, we just flew through some overall design instructions on creating your own DIY Wooden Aeroplane 3D Puzzle. I am very satisfied with how it turned out.

If you find this Instructable useful, do LIKE and SHARE this post and I will be submitting it to the Puzzle Design challenge! It's been a while that I have submitted something and just nice this competition and volunteering opportunity had got me writing again. Cheers!