Challenge 6: 3D-Printed Mechanism Integration

⏱️ ~3–5 hrs

Print, fit, and function. Bring your puzzle box to life by integrating custom 3D-printed mechanisms with your laser-cut frame.

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Why do this?

Hands-on hybrid making — combine additive and subtractive processes for real-world engineering experience.
Iterate with accuracy — printed parts test tolerances, clearances, and functionality against your frame.
Show full integration — demonstrate that your mechanisms fit and work seamlessly with the structure.
Industry alignment — most modern products use multiple manufacturing pipelines; this challenge mirrors that reality.

Overview

Design puzzle mechanisms in Autodesk Fusion (Personal License), export them as STL files, print them, and integrate with your laser-cut frame from Challenge 5. Align your work with the requirements.

What to Do (6 Steps)

Design in Fusion

Create all puzzle mechanisms intended for 3D printing.
Model with accurate dimensions to fit your laser-cut frame.

Prepare & Export STL Files

Export each part as an STL.
Large parts may be exported whole (no need to split unless necessary).

Create a Parts List (PDF)

Include name/ID, dimensions, filament type/material, and part function.

Locate a 3D printing service./h3>

Research and choose a location where you can get your own hands on a 3d printer (guide).

3D Print the Parts

Print all required parts; check accuracy of dimensions and fit.

Assemble with Frame

Integrate 3D-printed parts into your laser-cut frame from Challenge 5.
Ensure mechanisms function as designed.

Document the Process

Capture before-and-after photos of 3D-printed parts.
Photograph the final assembled puzzle box with mechanisms installed.

What to Submit

A publicly shared Google folder (so anyone can view) containing:

Parts list PDF (for 3D-printed parts)
Exported STL files from Fusion
Before & after photos of 3D-printed parts and the final assembled puzzle box

Pro Tips

Calibrate your printer bed and nozzle before long prints to avoid failed parts.
Use supports and proper orientation for complex shapes.
Test tolerances with small sample prints before committing to large pieces.

Scoring (Total: 150 pts)

Parts Documentation

3D printing parts list is clear, complete, and accurate.

25 pts

STL File Quality

STLs are well-prepared, scaled correctly, and functional for printing.

50 pts

Fabrication Quality

3D-printed parts are accurate, clean, and integrate properly with the frame.

30 pts

Assembly & Construction

Final assembly shows correct fit and function, with clear documentation.

45 pts

Challenge 6: Manufacturing Mastery

Challenge 6: 3D-Printed Mechanism Integration

Why do this?

Overview

What to Do (6 Steps)

Design in Fusion

Prepare & Export STL Files

Create a Parts List (PDF)

Locate a 3D printing service./h3>

3D Print the Parts

Assemble with Frame

Document the Process

What to Submit

Pro Tips

Scoring (Total: 150 pts)

Create a New Submission

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ManufacturingChallenge 6: Manufacturing Mastery

Challenge 6: Manufacturing Mastery

Why do this?

Overview

What to Do (6 Steps)

Design in Fusion

Prepare & Export STL Files

Create a Parts List (PDF)

Locate a 3D printing service./h3>

3D Print the Parts

Assemble with Frame

Document the Process

What to Submit

Pro Tips

Scoring (Total: 150 pts)

Create a New Submission