Given a set of puzzle pieces which don’t quite fit:
One makes them fit by re-drawing things so as to take the tool diameter into account — tool depth should take into account the stock thickness and the length of the cutting flutes, so if working with stock almost 1" thick, it wouldn’t be appropriate to use a #102 which only has 1/2" cutting flute length, so we will instead use a 1/4" tool:
Then draw in geometry for the puzzle:
Then draw in geometry to define how things will fit together:
and use Trim Vectors to cut up the geometry so that it can be fit together:
and edit things so that they fit together:
Duplicate the puzzle edge and rotate it:
and drag it into alignment:
and draw in the balance of the parts needed:
and join them:
Yes
Re-create the inset:
Insetting again, and then offsetting to the outside:
Arriving at:
which may then have toolpaths set up, which requires a further bit of offsetting:
Then set up toolpaths:
which cuts as:
If desired, add tabs:
Modify the pocket toolpath to stop at the tabs:
and then add an Outside Contour toolpath to finish the cut:
which previews as:
