Here are some coasters I just made specifically for this challenge. Theyre each comprised of “seven segment” style numbers 0 through 9. The numbers were machined out of starboard and the base was made out of pine and some other scrap wood I had on hand. I got the idea from a tik tok video of a similar puzzle that was 3d printed, and deisgned it in fusion 360.
Edit
Fusion 360 Link: https://a360.co/3hbtesa
CutRocket Link: https://cutrocket.com/p/5f3cc0e833932/
The design work was much easier than I expected, I ended up just making a sketch with a grid and connecting the dots to get the basic shape of the numbers. I then used the size of the numbers to create a box to hold them. After adding some fillets it was all done.
I also made a render to easily differentiate the numbers and solve the puzzle.
All of the CAM was sone with fusion 360. This was my first time working with the new manufacturing model feature and the arrange feature. Both features were really helpful and allowed me to do CAM on the numbers without “dissassembling” the model or needing to make copies. The toolpaths were just 2d contours with an 1/8in Amana plastic cutting endmill and then a 1/16in endmill to give the corners a tighter radius. The first set was cut with tabs but I had an issue with the tab sizing and spacing so for the next set I just used the painters tape and glue trick.
For the box I used an adaptive toolpath to rough out the middle with a 1/4in endmill and then came back with a 1/8in mill to clean up the edges. I used a 1/4in ball endmill with a steep and shallow path to add the fillet to the edge of the box. I’m really glad I added the fillet to the second box, I think it really makes the box stand out and look more professional.
The first round of machining didnt goes as well as I had planned, I accidentally set the tabs to be way too small and they ripped and caused the numbers to shift and get roughed up. I ended up repeating the process but instead of tabs I used painters tape and glue to hold down my stock. This worked flawlessly and the numbers came out really crisp. After manufacturing the base I realized my tolerances were off and the numbers could barely fit, so I ended up remaking it with a slightly larger opening and with the added fillet it turned out amazing.
While using the manufacturing model I accidentally chose the wrong sized stock and my router ended up cutting through my toe clamp on the first run. Thankfully all I had to do was 3d print another one.
After making sure everything fit correctly I stained the wooden boxes to be slightly darker in order to better contrast with the white numbers. And after that I had my final products. Hopefully theyll make some nice coasters for my new appartnment and at least be a fun conversation piece.
