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!