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Picture of Press-fit Construction Kit
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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!
 
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Step 1: Cut out the pieces on the laser cutter

Picture of Cut out the pieces on the laser cutter
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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!
gorskid1 month ago

What was the wattage on your Laser?

jramon21 year ago

cool


Kiteman3 years ago
Add some straight pieces, and this will make a cool construction set.