3D Printed A_Z Puzzle to Keep Them Busy!!

Here is a simple project I did for my two year old son. Just in time when he is identifying all letters around him, and learning colors.

Amazing!! at two and half, He knows A to Z. and colors.

The board size is 22CM by 30CM.

Each letter piece is 4cm in height and 1.2cm thick.

The design I made using sketchup. File included for those who will like to make modification.

Epilog Challenge: Lot's of project Ideas swimming in my head, mostly around little kids. If I have a personal laser cutter, together with my other tools 3D printer, CNC (all built by myself), those Ideas should be flying out one every week or two, making the little ones happy and encouraging me to Dream, Design build and of course share!!. VOTE

Step 1: Tools & Materials

3D printer.
CNC / Laser cutter.
Plywood/ board 22cm by 30 cm 5mm thick (2 Pcs)

The board can be any thickness using 5mm makes the total thickness to be 1cm!! should last really long. If you decide to use a different thickness board, consider changing the height of the puzzles/alphabets to make sure it fits.

Step 2: 3D Files & DXF

Download the STL files for 3d printing and DXF file for cutting the board using a CNC or Laser cutter. I have used both CNC and laser cutter with out any problem.

Laser cutting is way cool!!

Unless you have a really large 3D printer...Using your software of choice you will need to split the STL into parts, to allow it fit on the print bed. I print in two parts 13 alphabets at a time.

Or make selection to print in different color.

Notice the STL files are lying on the face, this is to give the printed parts a smooth top surface.

Step 3: The Wood Board

Using the DXF file cut one of the boards.
After then, glue together the two boards, the board which has not been cut will serve as the base.
Make the edges of the board less sharp by sanding them down, if possible use a a router to make the edges curve.

Step 4: Finishing

You know they will bite and chew!!

PLA plastics is safe but care should be taken with smaller kids!!

Leave the board natural un-painted and let it be stained/painted with the little one greasy hands, Otherwise apply some natural oil on it to protect the surface. If you must paint them, use child safe paints.

Need to pack it as a gift? use a shrink wrap film and don't forget to toss in a card behind before sealing.

If you make one please share a photo.