Laser Cut Stacked Einstein

In this tutorial you will learn how to create stacked jigsaws starting from a 3D design.

Step 1: Download and Install Slicer for Fusion 360

Link to downloading Slicer for Fusion here.

Step 2: Import a 3D Model

We prepared a smaller and easier to process 3d model. Import the Einstein simplified model.

Alternatively, Download the 3D model Einstein bust from Thingiverse . Just the file “EinsteinBustTongue.stl” is needed. The file is quite big, it will probably need a powerful computer. Then just Import the 3d model EinsteinBustTongue.stl in Slicer.

Step 3: Set the Units to Mm

Step 4: Set the Desired Size for the Model. We Suggest Minimum 10cm Height

Step 5: Choose the Desired Sheet Format in Manufacturing Settings

Step 6: Choose the Construction Technique Stacked Slices

Step 7: Go to Manufacturing Settings

In manufacturing settings click on the small gear icon in order to see the advanced options at the bottom of the screen:

Step 8: Set the Material Thickness to the One You Wish to Use

Slot offset is usually 0.010 for most laser cutters.

Step 9: Set the Dowels

Choose “cross”: setting two dowels makes the puzzle easier, as the slices will be unable to rotate and their orientation will be defined by the dowels.

Step 10: How to Design a Stacked Puzzle With Slic3r

As a reference, here are some information on how to create a stacked slice puzzle from a 3D model with other free softwares, namely Slic3r and Sketchup.

With Slic3r

Slic3r is an open source slicing software commonly used for 3D print. Here a quick guide on how to slice a 3D model to laser cut it as a puzzle.

Modify the printer settings and as nozzle diameter set a very large size, for example 10 mm.

In the print settings tab set a layer eight that is the same of the material you wish to use, for example 2 mm.

From the FILE menu select SLICE TO SVG

Select the 3D model you wish to use and choose a location and name for the file.

An .svg file with the chosen name will be saved in the chosen location.

Modify the .svg file with inkscape Open the svg file with Inkscape. The generated slices will be white, so they won’t be visible. Change the line color.

Select every slice and move it. Arrange the slices one by one next to each other, in order to cover the sheet format you wish to use for the laser cutter.

Save the file as required from your laser software.

Step 11: How to Design a Stacked Jigsaw With Sketchup

Sketchup is a free 3D software.

Choose a model from the Sketchup library 3D warehouse or import one.

Make a group of your model. Create a cutting plane and make copies at the depth of the material to be cut. Lap them over your model. Select all and intersect with model. Delete extra lines and organize your slices for export.