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This Instructable is for a press-fit construction kit that is made up of just two simple pieces.  You can cut out the pieces on a laser cutter using any material you'd like (I used plywood) and start construction your own spherical shapes!

Step 1: Cut Out the Pieces on the Laser Cutter

I created a CAD model of the kit in SolidWorks.  The CAD files, as well as exported DXF files ("connector" and "slot_2") are included in the attached zip file below.  There is also a Corel Draw file and Illustrator file.  Use whichever file works for your laser cutter.  I was using an Epilog laser cutter at a speed and power setting of 5 and 100.  I cut my pieces out of 1/4"-thick plywood.

If you'd like to adjust the size of the pieces, you can edit the slot_size and slot_depth variables in the text file "slot_variables.txt".  Editing the numbers in this file will automatically update the CAD model.

Step 2: Construct a Sphere

You can make a lot of different shapes with the construction kit pieces.  The images below outline the steps for making a sphere.  Play around with the pieces to make new shapes!
<p>What was the wattage on your Laser?</p>
<p>cool</p><p><br></p>
Add some straight pieces, and this will make a cool construction set.<br><br>

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