A ball octahedron puzzle which interlocks. The assembled puzzle is quite stable and can be tossed around without fear of falling apart.
It is made from four simple pieces: One Y and three U's. The pieces must flex slightly as it goes together. A copy made from PLA was a failure: too brittle. A second version made from PETG works. Do not make this model from PLA, it will break.
Assembly is confusing but not difficult once you know the trick. Do not force the assembly or you can break the puzzle! To assemble with minimum force you need to move all three U's at the same time. The same move in reverse takes the puzzle apart.
Each piece is cut in half so that no supports are needed. Print 2 copies of the (half) Ypiece and 6 copies of the (half) Upiece. I recommend a layer height of 0.15 mm or smaller for good sphere resolution.
IMPORTANT: The U pieces are under stress during assembly and I recommend strengthening their joints. This is most easily done by increasing the number of perimeters. I recommend at least 4. This will keep the pieces from breaking. The Y piece is not under stress and does not need to be strengthened (the yellow Y in the photos is actually made from PLA).
The halves are glued together with superglue. Each piece contains holes for alignment. After cleaning the holes out (if necessary) take a scrap piece of 1.75 mm filament. Insert the filament into a hole and cut it off such that about 3 mm is sticking out. After each hole has a piece of filament, fit the other half in place. If the fit looks good, remove and glue the halves together.
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