A Trio of "Keychain Puzzles".

Since the 1940s, many companies around the world have created small three dimensional plastic puzzles known as "keychain puzzles". These puzzles usually consisted of around six puzzle pieces, and when correctly assembled, created a keychain figurine. In this Instructable, I've reproduced three of my favorite keychain puzzles from my youth; the dog, the giraffe (ok, maybe my wife's favorite as well, sigh) and the elephant. And if you wish to customize these puzzles I've also included the Autodesk Fusion 360 CAD files for each.

Each step of this Instructable contains the puzzle pieces for each of the three puzzles. SPOILER ALERT: Along with the puzzle pieces is a video showing how the puzzle pieces are assembled, so if you wish to figure out how each puzzle is assembled on your own, don't watch the videos!

The puzzle pieces are small, require no support, and print fairly quickly, making them a great introduction to 3D printing with the result being a three dimensional keychain puzzle to boot!. I printed all my puzzle pieces at .1mm layer height with 20% infill. After printing I used jewelers files and Micro Mesh sanding strips along with plenty of patience to remove the build plate "ooze" (sometimes referred to as "elephant foot") from each piece. Depending on your slicer, printer, printer settings and the colors you chose, you may need more or less filing and sanding. You will want the pieces to fit snuggly, so "sneak in" on the filing and sanding.

I hope you enjoy them!

As usual I probably forgot a file or two or who knows what else, so if you have any questions, please do not hesitate to ask as I do make plenty of mistakes.

Designed using Autodesk Fusion 360, sliced using Ultimaker Cura 4.6.1, and 3D printed in PLA on an Ultimaker 3 Extended and an Ultimaker S5.

Step 1: The Dog.

Prior to puzzle assembly of the dog, I pressed "Head.stl" onto "Neck.stl".

Step 2: The Giraffe.

Step 3: The Elephant.

Prior to puzzle assembly of the elephant, I pressed "Head.stl" onto "Neck.stl".

Comments

[Rwmc60]

Hello,... I just saw your creations and have been a collector of this type of puzzle for 50 years. I have over 200 different styles and like that someone is still making them.

[gzumwalt]

Hi Rwmc60,

Thank you very much, and congratulations on your collection!

Greg

[Build_it_Bob]

Hi Greg! I knew this was your handiwork right away. I also had those toys as a child, I would try to put them together in whatever crazy way I could. There were other toys at my Grandparents: Mini Bricks, Major Matt Mason, Billy Blastoff...they also liked to play board games and Yahtzee with us. Boy do I miss them!
I bet your grand kids can't wait to visit and see what you made!
As always, thanks for sharing,
Bob D

[gzumwalt]

Thanks Bob! Yes, every Friday they come down to the basement and see what's next. Today they will see this: https://youtu.be/yJjaPf54c6E .

Many thanks again!

Greg

[Nikolaos Babetas]

Great design!

[gzumwalt]

Thank you!

Greg

[feuerwehrmann]

Hallo from Germay,
in east-Germany we have the same as "Berliner Bär" / bear as city arms. It's from the 70er. I have it still.
Great work. I want to print your animals. Thanks.

[gzumwalt]

That is very cute! Thank you so very much!

Greg

[Marve48]

Sweet. It reminds me of a toy I had when I was a kid.

[gzumwalt]

Thanks Marve48, I'm glad you liked them!

Greg

[Penolopy Bulnick]

These are so cute!

[gzumwalt]

Thanks Penolopy! They're very easy to 3D print.

Greg