GB2499381A

GB2499381A - 3D puzzle formed using CAD and CAM processes

Info

Publication number: GB2499381A
Application number: GB201202011A
Authority: GB
Inventors: Goor Moshe; Tiran Moshe; Doron Moshe
Original assignee: Individual
Current assignee: Individual
Priority date: 2012-02-06
Filing date: 2012-02-06
Publication date: 2013-08-21
Also published as: GB201202011D0

Abstract

A three-dimensional (3D) puzzle including multiple 3D puzzle-pieces is designed and manufactured using computer aided design (CAD) and manufacturing (CAM) processes. The 3D puzzle is designed using a CAD module 110 by receiving a 3D object model, determining division contours defining puzzle-pieces of the 3D object model, creating a piece-model associated with each of the puzzle-pieces, and generating piece-model data 40 relating to each respective 3D piece-model. The puzzle is manufactured using a CAM module 120, by receiving the piece-model data and creating each puzzle-piece 61, 62, 63 separately in accordance with the received 3D piece-model data using at least one computer-aided production process 200 such as a milling machine or a 3d printer. The 3D piece-models may comprise 3d models of the respective puzzle-pieces, or 3D models of moulds of the respective puzzle-pieces. The 3D object model may be created using the CAD module. Alternatively, a 2D picture or image may be converted to a 3D object model using the CAD module. Determination of the division contours may be carried out manually using the CAD module, or carried out automatically by the CAD module.

Description

Method and System for Computer Aided Manufacturing of 3D Puzzles using

Computer Generated Modeling

FIELD OF THE INVENTION

[001] The present invention generally relates to puzzle production systems and 5 processes using computer generated modeling and computer-aided manufacturing.

BACKGROUND OF THE INVENTION

[002] 2D Puzzles such as jigsaw puzzles are usually manufactured by creating a picture print covering a board and then cutting the 2D picture into the puzzle-pieces, e.g. by using a cutting die, according to a predefined puzzle pattern, puzzle-piece

10 [003] A US patent No. 5,251,900 by Paul Gallant discloses a puzzle formed of a plurality of puzzle-pieces, which when assembled create a self-standing three-dimensional (3D) building structure. The puzzle-pieces are of irregular polygonal shape interlocking one another, where all puzzle-pieces are flat planar blocks. The building walls can be constructed by interlocking the matching pieces thereby creating the 3D puzzle.

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SUMMARY OF THE INVENTION

[004] According to some embodiments of the present invention, there is provided a method of manufacturing a three-dimensional (3D) puzzle including multiple 3D puzzle-pieces. According to these embodiments, the method includes: 20 (1) receiving a 3D object model; (2) determining division contours of puzzle-pieces of the 3D object model; (3) creating a piece-model associated with each of the puzzle-pieces, where the 3D piece-model is a 3d model of the respective puzzle-piece or a of a mould of the respective puzzle-piece, according to graphical features of the object model and the division contours, where the operations of receiving, 25 determining and calculating may be carried out by using at least one graphical software tool, which enables outputting 3D piece-model data of each respective puzzle-piece of the 3D puzzle; (4) receiving each respective 3D piece-model data; and (5) creating each puzzle-piece of the 3D puzzle separately, according to each received respective the 3D piece-model data, using at least one computer-aided 30 production machinery.

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[005] Optionally, the 3D piece-model data includes commands for allowing the production machinery to create the respective 3D puzzle-piece or a respective 3d mould of each the respective 3D puzzle-piece thereby.

[006] According to one aspect of the invention, the 3D puzzle is a relief 5 puzzle including a 3D embossment over at least one side thereof.

[007] The method may additionally include the step of creating the 3D object model by using the same or another graphical software tool. Creating of the 3D object model may include: (i) receiving a two-dimensional (2D) picture; and (ii)

converting the received 2D picture into the 3D object model, using the graphical

10 software tool.

[008] According to additional or alternative aspect of the present invention, the piece-models are created by using a first graphical software tool enabling modeling and creation of piece-model data file of each respective piece model is carried out using another graphic software tool enabling receiving each respective

15 piece-model and creating a corresponding data file including machine commands for allowing the production machinery to read the commands and produce each respective puzzle-piece thereby.

[009] The division contours may be determined manually by a user selecting curvature lines over at least one side of the object model, using designated contour-

20 defining tools of the graphical software tool. Alternatively, the division contours are determined automatically by the graphical software tool, according to a predefined program enabling both the contour definition and the calculating of the 3D piece-models of the 3D puzzle, e.g. by receiving a number of puzzle-pieces and defining a virtual grid over one side of the 3D object model, according to the number of puzzle-pieces and dimensions 25 of the side of the 3D object model.

[0010] In the cases in which the 3D piece-model is a 3D model of a mould of the respective puzzle-piece, the mould of each respective puzzle-piece may be created from the respective 3D piece-model of the respective mould, where the respective puzzle-piece is created by using the respective puzzle-piece mould e.g. by injecting mould materials

30 thereto.

[0011] According to some aspects of the present invention, the creation of each respective puzzle-piece comprises: (i) first creating each respective puzzle-piece using a 3D model of the puzzle piece itself; (ii) then using each of the 3D puzzle-piece to create

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moulds therefrom; and (iii) mass producing each respective puzzle-piece from the puzzle-pieces' moulds, using at least one injection-technique.

[0012] According to other aspects of the present invention, there is provided a system for manufacturing a three-dimensional (3D) puzzle including multiple 3D

5 puzzle-pieces. According to these aspects, the system includes: (1) a computer system such as a PC computer, a laptop or any other computerized system or device, where the computer system includes (i) a first module, which receives a 3D object model, enables determining division contours of 3D pieces of a 3D puzzle of the object model and creates a 3D piece-model associated with each of the puzzle-

10 pieces, according to graphical features the 3D object model and the division contours, outputting 3D piece-model data of each respective puzzle-piece of the 3D puzzle, where the 3D piece-model is a 3D model of a respective puzzle-piece or a mould of a respective puzzle-piece; and (2) at least one computer-aided production machinery, which enables receiving 3D piece-model data of each puzzle-piece and

15 producing a respective the corresponding 3D puzzle-piece according to the piece-model data, wherein each 3D puzzle-piece is created separately, according to each received respective 3D piece-model data, using the production machinery.

[0013] The computer-aided production machinery may comprise at least one of: a milling machine (such as a computer numerical control (CNC) milling machine); a 3D

20 printer; an electro-discharge machining; laser-based production machinery.

[0014] According to some aspects of the present invention, the production machinery comprises at least one milling machine and at least one moulding machine for casting moulding materials into a predefined mould, wherein the mould is created using the milling machine.

25 [0015] The system optionally further comprises a second computer module for creating piece-models' data files from the 3D piece models, where the second module receives the 3D piece models of from the first module and converts each such 3d piece-model into a data file that includes the machine commands. The second module may be operated by the same or another different computer system.

30 [0016] Optionally, the graphical software tool enables receiving a two-dimensional (2D) picture and automatically converting it into a 3D object model.

[0017] According to some aspects of the present invention, the first module further allows a user to select a number of puzzle-pieces and automatically determine the contour

lines of the respective 3D object model by determining a grid defining the division contours, according to the selected number and according to dimensions of the 3D object model; and/or enables the user to determine (e.g. select) surface textures of the 3D puzzle where the production machinery allows creating the surface textures accordingly.

5 [0018] The computer system is optionally embedded in the production machinery allowing receiving 3D piece models and automatically producing them.

[0019] According to some aspects of the present invention, there is provided a three-dimensional (3D) puzzle comprising a multiplicity of 3D puzzle-pieces,

wherein the puzzle is produced by receiving a 3D object model; determining

10 division contours of puzzle-pieces of the 3D object model; creating a piece-model of each of the puzzle-pieces, according to graphical features of the object model and the division contours, wherein the receiving, determining and calculating are carried out, using at least one graphical software tool, which enables outputting and/or storing 3D piece-model data of each respective puzzle-piece of the 3D

15 puzzle, where the 3D piece-model data comprises commands data for allowing at least one production machinery to create 3D piece models of the 3D puzzle thereby, and wherein each respective 3D puzzle-piece is created separately, according to each received respective 3D piece-model data, using the production machinery.

[0020] The 3D puzzle optionally includes at least one support member for

20 supporting at least some of the puzzle pieces once joined to one another such as, for example, a supporting pole and/or board.

[0021] According to one aspect of the invention, in cases in which the puzzle includes a support board, the board may comprise protrusions or sockets that interlock with corresponding sockets or protrusions of their respective puzzle-

25 pieces.

[0022] According to other aspects of the present invention, there is provided a relief puzzle comprising a multiplicity of relief puzzle-pieces, where the relief puzzle is produced by receiving a puzzle object model; determining division contours of puzzle-pieces of the object model; creating a piece-model of each of the

30 puzzle-pieces, according to graphical features of the object model and the division contours, wherein the receiving, determining and calculating are carried out, using at least one graphical software tool, which enables outputting 3D piece-model data of each respective puzzle-piece of the relief puzzle, the 3D piece-model data

comprises commands data for allowing at least one production machinery to create 3D piece models of the relief puzzle thereby, and wherein each respective puzzle-piece is created separately, according to each received respective 3D piece-model data, using the production machinery.

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BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Fig. 1 is a flowchart, schematically illustrating a process of manufacturing 3D puzzles using computer generated modeling, according to some embodiments the present invention.

10 [0024] Fig. 2 schematically illustrates a system for manufacturing 3D puzzles using computer generated modeling, according to some embodiments the present invention.

[0025] Fig. 3 shows a two-dimensional picture from which a 3D puzzle model can be created, according to one embodiment of the present invention.

[0026] Fig. 4 shows a 3D model of the race car shown in the picture of Fig. 3, where 15 the 3D model is carried out by using the 2D picture, using a software modeling tool (i.e.

Maya software).

[0027] Fig. 5 shows the 3D model of the race car shown in Fig. 4, including grid lines as dividing contours defined according to selected number of rows and columns, which defines the number of puzzle-pieces of a corresponding relief puzzle of a race-car.

20 [0028] Fig. 6 shows a 3D puzzle created by using the 3D model of the race car, which has been divided into piece models according to the grid line, where each puzzle-piece of the relief puzzle shown was manufactured separately according to its respective piece-model.

[0029] Fig. 7A shows a computer generated 3D model of a 3D head shaped object. 25 [0030] Fig. 7B shows a partial division of the 3D model of fig. 7A into slices pieces models, according to some embodiments of the present invention.

[0031] Fig. 8A shows computer generated 3d pieces models of one of the slices shown in Fig. 7A, in a joined position, according to some embodiments of the present invention.

[0032] Fig. 8B shows computer generated 3d pieces models of one of the slices shown 30 in Fig. 7A, in an exploded position, according to some embodiments of the present invention.

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[0033] Fig. 9A shows a photograph of a 3D puzzle of the head made by using a CNC milling machine, in a joined position, according to some embodiments of the present invention.

[0034] Fig. 9B shows a photograph of the same 3D puzzle of the head as the one

5 shown in fig. 9A, in a position in which some of the puzzle pieces are removed to show how a supporting pole connected to a base piece of the puzzle allows holding the joint pieces together, according to some embodiments of the present invention.

[0035] Fig. 1 OA is a cross sectional view of a virtual part of a relief puzzle, according to some embodiments of the present invention.

10 [0036] Fig. 10B is a cross sectional view of two separated pieces of a relief puzzle, according to some embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0037] In the following detailed description of various embodiments, reference is made 15 to the accompanying drawings that form a part thereof, and in which are shown by way of illustration specific embodiments in which the invention may be practiced. It is understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.

[0038] The present invention, in some embodiments thereof, provides a 3D puzzle 20 such as a relief puzzle or a 3D object puzzle including multiple 3D pieces as well as methods and systems for producing thereof using computer generated (CG) modeling. The methods include receiving a 3D object model, which is a geometric/mathematical representation of a 3D object, determining division contours of puzzle-pieces of the 3D object model such as grid lines thereof and creating a piece-model of each of the puzzle-25 pieces, according to graphical features of the object model and the division contours. These steps are carried out by using one or more graphical software tool such as computer aided manufacture (CAM) software, which enables outputting 3D piece-model data of each respective puzzle-piece of the 3D puzzle. Each such piece model data includes commands data for allowing production machinery to receive this data (as a data file of the respective 30 piece model) and create the respective 3D puzzle-piece thereby. The file(s) including the piece model data of each puzzle-piece is then received by the production machinery, which

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can create each puzzle-piece separately, or in batch, according to each received respective 3D piece-model data.

[0039] The production machinery may include any known in the art machinery that can produce 3D objects by receiving CG models related data and commands - such as 3D 5 printers and/or a computer numerical control (CNC) milling machine enabling to receive CAM generated data files and translating commands therein into machine operations for curving or cutting the shape of each respective puzzle-piece, or for making moulds for moulding 3D puzzle-pieces, or any other computer aided manufacture machinery such as EDM (electro-discharge machining) or laser-based production machines.

10 [0040] Any material known in the art such as plastic, wood, metal and the like can be used to create these puzzle-pieces depending on production machine limitations and accuracy and the manufacturer's requirements. For example, the manufacturer may choose magnetic metallic materials to produce a magnetic 3D puzzle where the puzzle-pieces can stay attached to one another due to magnetic attraction between them, or use wood or 15 plastic due to cost, safety and/or environmental considerations.

[0041] Additionally or alternatively, the design of each puzzle-piece further includes a protrusion or socket member that is designed to fit into a corresponding socket or protrusion on a supporting member such as a board, which may be a part of the puzzle assembly product, where the supporting member allows holding the connected puzzle-20 pieces together. For example, in case of a relief puzzle, in which the lower surface does not include the 3D curvature of the relief object, each puzzle-piece may include a protrusion at its bottom surface that is designed to fit to a board including corresponding sockets,

located according to the positioning of their respective matching puzzle-pieces. The board enables holding each puzzle-piece, by allowing the user to insert the protrusion member of 25 the respective puzzle-piece to its corresponding board-socket, according to the right location of the respective puzzle-piece in relation to the other pieces. The puzzle-pieces may interlock or lock on to their corresponding sockets through an additional fastening mechanism such as a snap mechanism and the like included in the design of the protrusion and/or of the socket for further fastening each puzzle-piece to the supporting board. 30 According to some embodiments of the present invention, the additional protrusion/socket of the puzzle-pieces may be designed and manufactured in same manner, where the piece-model of each puzzle-piece includes its protrusion/socket design, where the production

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machinery creates each puzzle piece or puzzle piece mould including the special protrusion/ socket.

[0042] Since the puzzle-pieces are produced separately, rather than being cut off from a 3D shape, a much better accuracy can be achieved. An improved accuracy is achieve

5 since the determining of the contour lines separating the puzzle parts are virtually done through software tools instead of by the cutting machines and then each is produced (e.g. by milling or moulding) separately. Another advantage of this method is that each puzzle-piece can be mass produced creating many parts of that same puzzle-piece at a time where whenever one or more are damaged or of low quality it is easily replace and can easily fit 10 to matching neighboring puzzle-pieces - preventing the case in which the entire puzzle has to be dispensed. This is very cost effective as well as environmentally friendly since this process saves time, money and raw material that would have been otherwise wasted if not recycled.

[0043] According to some embodiments of the present invention, the 3D object model 15 may be created as part of the process or taken from a readymade models' source such as from a models' archive. The 3D object model may then be further processed allowing the user to set the number of puzzle-pieces thereof and division contours (e.g. grid lines) for dividing the 3D object model into puzzle-piece-models. The division contours may be determined automatically once the user sets the number of pieces (e.g. by using a 20 designated Graphical Use Interface (GUI)) by determining a virtual division grid over the 3D object model. For example, in case the 3D object model is of a relief puzzle meaning that one side is curved while the other five sides are flat and perpendicular to one another, the grid will divide the semi-box shaped object model into squares or rectangular shapes or any irregular shapes, which can fit into each other, according to the selected number of 25 pieces.

[0044] The graphical software tool may then create puzzle-piece-models according to the shape and dimensions of the 3D object model and according to the division contours. Then, a piece-model data may be created for each piece-model of the 3D puzzle (e.g. by using CAM software) for allowing the production machine to enable forming (e.g. by

30 milling) the respective puzzle-piece by receiving commands embedded in this dat.

[0045] The piece model data of each piece-model may be saved as a separate data file or as a single data file indicative of each piece-model. In case of multiple data files, the

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production machinery allows receiving each such file and creating each separate puzzle-piece according to commands embedded in the respective data file.

[0046] The 3D object model of the 3d puzzle and/or the piece-models may be created by using a first graphical software that uses any modeling technique known in the art such

5 as Maya, computer aided design (CAD), SolidWorks and the like, while the creation of the piece-models' data files is done by using a second tool such as CAM.

[0047] Reference is now made to Fig. 1, which shows a flowchart, schematically illustrating a process of producing a 3D puzzle including multiple 3D puzzle-pieces, according to some embodiments of the present invention. According to these

10 embodiments, a 3D object model is received or created by a graphical software tool (e.g. CAD or Maya) 11. Division contours are then determined 12 either manually be the user or automatically. Once the division contours are determined and defined, piece-models are created 13 (e.g. by using the same graphical software tool). Another software tool or the same tool then creates data files 14 including machine operation commands associated 15 with the specific production machinery that will produce these puzzle-pieces and with the piece-models' graphical features.

[0048] The created data files can then be received by the production machinery 15, which reads the commands in these files and executes machine operations thereby to create each puzzle-piece separately 16 (or piece-moulds for making the puzzle-pieces).

20 [0049] According to one embodiment of the invention, CNC milling machine is used for producing the puzzle-pieces and CAM software tools are used to create data files of each respective piece-model of the puzzle. In this case, the CNC milling machine produces each puzzle-piece by machining it, using milling cutters at different directions and optionally (depending on machine type) also by moving the raw material itself. The 25 commands embedded in the data file of the respective puzzle-piece enable operating the machine to perform the milling of a solid raw material placed thereon. This means that the machining/milling process is done substantially automatically.

[0050] According to another embodiment, the production machinery includes a CNC milling machine as well as a moulding machinery, where the milling machine enables 30 preparing casting moulds of the puzzle-pieces (a different mould for each different piece) and the moulding machinery allows pouring (e.g. injecting) liquidized materials such as liquid plastic or metal compounds into the moulds for producing each separate puzzle-piece. Another technique that can be used is to manufacture the moulds by milling (e.g.

using a CNC milling machine) and then go directly to injection moulding. Optionally, each mould of each puzzle-piece may be made by first creating one respective puzzle-piece (e.g. using CNC milling), then using the respective 3D piece to create a mould therefrom (e.g. by casting over the piece) and then use the respective mould to mass produce the 5 respective puzzle-piece, e.g. by injecting plastic based materials into the respective mould.

[0051] According to some embodiments of the present invention, as mentioned above, the 3D object model may be also created using one or more modeling tools (such as CAD, Maya and the like). In some cases, especially yet not exclusively in the case of producing relief puzzles, the 3D model may be created by using a 2D model or picture and then

10 converting the received 2D picture into a 3D (relief) object model.

[0052] Creating the 3D object model may be done manually by a user or automatically, where the graphical software tool enables the manual conversion by including a GUI allowing the user to manually design the corresponding 3D object model and the automatic conversion is enabled by using one or more designated predefined 2D to 3D conversion

15 programs.

[0053] According to some embodiments of the present invention, other graphical features of the puzzle may be set by the user at the modeling stage in which the 3D object model is designed. For example, the user may define one or more textures for the surface of the puzzle-pieces, e.g. defining a different texture to each part of the 3D object model,

20 where the commands also include the texture of each part of the pieces' surface to allow the milling machine to create this texture(s).

[0054] Reference is now made to Fig. 2, schematically illustrating a system 500 for producing a 3D puzzle including multiple 3D puzzle-pieces, according to some embodiments of the present invention. The system 500 includes at least one computer-

25 aided production machinery 200 such as a CNC milling machine or a 3D printer; and a computer system 100 (e.g. PC, laptop, tablet computer and the like) operating a first module 110 for creating and outputting 3D piece models data files of a received 3D object model for allowing manufacturing of puzzle-pieces of the 3D object, according thereto. The first module 110 may include one or more graphical software tools such as Maya, 30 CAD and the like, allowing receiving or creating 3D object models, determining division contours of 3D pieces of a 3D puzzle of each respective object model and calculating a 3D piece-model of each of the puzzle-pieces, according to graphical features the 3D object model and the division contours.

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[0055] According to some embodiments of the present invention, the computer system 100 further includes or is operatively associated with a second module 120, which includes a different software tool such as CAM for receiving the 3D piece-models created by the first module 110 and converting each piece-model into a data file 40 that includes

5 commands data for allowing the production machinery 200 (such as that illustrated as part of the system 500) to create the respective 3D puzzle-piece thereby. The data files 40 are then received by the production machinery 200, which translates the commands therein into machine operations. For example, the production machinery 200 includes a CNC milling machine or a 3D printer that can machine raw solid materials such as plastic, wood 10 and/or metal automatically according to input programming commands. The data files 40 may be saved on separate hardware storage by the user, using the second module 120, such as a disc, a disc-on key and then downloaded to the production machinery 200 computer system. Alternatively the computer system 100 and modules 110/120 that generate or receive the puzzle-pieces' models may be embedded in the production machinery 200 15 enabling to automatically translate 3D models into the production machinery's 200

commands (e.g. by using advanced 3D printers). Alternatively, the modules 110 and 120 are installed and operated by a computer system that also connects to the production machinery 200, where the data files can be stored in the computer archives (located in the computer system 100) and then operated by selecting them therefrom through the 20 production machinery 200. In this case, a communication link (e.g. an internet link or any other networking wired or wireless link) exists between the production machinery 200 and the computer system 100.

[0056] Using 3D piece-models for creating each puzzle-piece separately through the production process either by manufacturing batches of each puzzle-piece or by

25 manufacturing each 3D puzzle at a time depending on manufacturer's requirements and system 500 definitions.

[0057] Using 3D modeling of each puzzle-piece or puzzle-piece mould separately by virtually dividing the 3D virtual object model into virtual puzzle pieces, in which the distance between each two interfacing surfaces of respective interlocking or interfacing

30 puzzle-pieces is virtually zero, and then producing each such puzzle-piece separately using state of the art computer-aided production machines such as 3D printers or CNC milling machines allow achieving high performances and accuracy levels of puzzle-pieces interfacing. In "puzzle-pieces interfacing" we mean that once manufactured adjacent

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puzzle-pieces that are meant to interface (e.g. by interlocking or by simply touching through a flat or a curved surface), when interfaced, can have a very low maximal distance between one another through their interfacing surfaces. This means that the interfacing puzzle-pieces interface one another almost to the zero distance interfacing level of their 5 corresponding virtual design. This is achieved since accuracy level only depends upon the accuracy of the production machinery's 200 cutting tools (i.e. dies' performances) in some CNC milling machines, for instance, production performances accuracy level reaches 0.001 mm meaning that the maximal distance between interfacing surfaces of two adjacent interfacing puzzle-pieces is 0.002mm, in this case.

10 [0058] Figures 3-6 show the outputs of the modeling and production processes of a 3D relief puzzle of a racing car, according to some embodiments of the invention. A 2D racing car picture 71 was used, as illustrated in Fig. 3 to create a 3D object model 72 by using Maya graphical software tool. As shown in fig. 4, the 3D object model is of a box shape having five flat sides while the sixth side includes an embossment of the racing car. The 15 user then defines the number of puzzle-pieces he wishes to produce and optionally the precise dimensions of the puzzle (e.g. where the proportions are taken from the 2D picture 71 and the scale can be modified. A grid dividing contours set is automatically calculated and illustrated over the 3D model 73 (as illustrated in Fig. 5) according to the selected pieces number. At this point the model is virtual and therefore the space between the pieces 20 of the puzzle in their interfacing surfaces is null. Once the grid is calculated and set the

Maya program allows virtually cutting the 3D module vertically thereby - to calculate and create the 3d piece models of the relief puzzle. At this point a CAM program is used to convert the piece models data into a milling-machine readable data file. Fig. 6 shows a 3D actual relief puzzle 74, as produced by a CNC milling machine from the data files 25 produced by using the CAM program, made of wax.

[0059] As illustrated in Fig. 6, the Maya program also allows designing different textures to different objects over the embossment of the relief puzzle 74 where the CNC milling machine allows creating these actual textures over the objects' surfaces.

[0060] According to some embodiments of the present invention, to prepare the relief 30 model, a curved zero thickness virtual surface may be created and once the curved surface representing the image embossment of the relief is created a complete 3D model of the relief object may be calculated and/or designed. Then the division curves (cut lines) of the puzzle may be graphically determined over the 3D model image (either manually or

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automatically according to input data such as the number of pieces) to allow creating 3D models of each puzzle piece of the relief. To manufacture each puzzle piece separately, the machining may include, in some cases, receiving a raw material having a predefined shape such as a box or disk shape, cutting all surfaces of the puzzle piece other than the 5 embossment surface and engrave the embossment of the particular respective puzzle piece using engraving tools of the production machinery. For example, using CNC milling machinery engraving die tools such as milling cutters may be used to form the embossment surface of the puzzle piece.

[0061] Reference is now made to Figures 7 A and 7B, schematically illustrating a 3D 10 model 81 of a 3D head object. The head 3D model 81 is virtually divided into virtual slices

81a-81f each slice can be further divided into pieces each defining a 3D piece-model of the respective puzzle-piece. Figures 8a and 8B show one of these slices 81e showing how at least some of the slices can be divided into pieces such as pieces 21a-21d. Additionally or alternatively, at least some of these slices such as slice 81 e can include a middle opening 15 created when all pieces of the slice are connected together or, in case of an undivided slice, an opening of the slice. The openings of all the pieces may be designed to align creating a coaxial opening shape for receiving a corresponding supporting member such as a supporting pole holding all slices together. The computer generated piece-models of these slices and pieces in this head 3D model 81 example, were created by using the Maya 3D 20 computer modeling software. Each slice may be of a different thickness where the number of slices, pieces and the dimensions thereof determine the complexity level of the 3D puzzle. By saving each slice as a separate model, they can be manufactured using CNC machining or a 3D printer using the same process as described in the manufacture of the relief puzzle. In this case, for example, each piece-model file was saved as an object file 25 that could be read by a 3D printer - including 3D printer readable commands for producing each respective puzzle-piece.

[0062] The results can be shown in photographs presented in Figures 9A and 9B showing a real world version of the sliced head 3D puzzle 300. Figures 9a and 9B show where the pieces join (interface), due to the low resolution of the 3D printer. Should the

30 slices be manufactured using a CNC mill or a higher resolution 3D printer or printer options, the joins will be very hard to discern.

[0063] As shown in Figures 9a and 9B the 3D head puzzle 300 includes slices 311-322 and a bottom support 330 connected to a pole supporting member 310, where all the slices

311-322 are threaded through the pole 310 or build around it. Some or all of the slices 311-322 are divided into pieces such as slice 311 including four pieces two of them are shown in the photo of fig. 9B: pieces 311a and 31 lb.

[0064] As mentioned above, the computer generated model of the 3D object is 5 virtually split along lines that have zero thickness, meaning that the pieces fit perfectly together in the virtual environment. The process of manufacturing each piece separately using computer aided machinery, as previously mentioned, allows getting close to this perfect fit. Something that isn't possible using traditional tools for manufacturing puzzles (e.g. by creating a real 3d object and then cutting/dividing it into puzzle pieces).

10 [0065] CNC milling machines are capable of reaching an accuracy of a micrometer (0.001mm). So for example should a piece of the 'Relief puzzle be manufactured this way with the aim of it being 30mm x 30mm, a CNC milling machine can be within 0.001 of these dimensions, as mentioned above. 3D printers today are able to achieve an accuracy of 0.05 - 0.1mm, which is accurate enough so that the human eye cannot distinguish any

15 deviation. Moreover, 3D printers technology is currently further developed so that it is very likely that it will get closer to the accuracy if CNC milling in the future or even exceed it.

[0066] This level of accuracy can be confirmed and checked using a coordinate-measuring machine that is a 3D device for measuring the physical geometrical

20 characteristics of an object. These devices can measure extremely accurately, and can achieve the level of a micrometer.

[0067] Reference is now made to Figures 10A and 10B, schematically illustrating virtual and actual dividing of relief puzzle pieces, respectively, according to some embodiments of the present invention. Fig. 10A shows how a virtual division line ml of

25 zero thickness is made (e.g. manually by the user using graphical tool(s) or automatically in case of a relief puzzle, where the split lines are determined according to predefined conditions such as number of puzzle pieces and the like). XI, x2 and x3 represent the local direction (slope) of the outer surface of the relief. Fig. 10B shows how the virtual division line is translated into two separate puzzle pieces.

30 [0068] Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the

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following invention and its various embodiments and/or by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different elements, which are disclosed in above even 5 when not initially claimed in such combinations. A teaching that two elements are combined in a claimed combination is further to be understood as also allowing for a claimed combination in which the two elements are not combined with each other, but may be used alone or combined in other combinations. The excision of any disclosed element of the invention is explicitly contemplated as within the scope of the invention.

10 [0069] The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its

15 use in a claim must be understood as being generic to all possible meanings supported by the specification and by the word itself.

[0070] The definitions of the words or elements of the following claims are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially

20 the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it

25 is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a sub-combination or variation of a sub-combination.

[0071] Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as

30 being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.

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[0072] The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted and also what essentially incorporates the essential idea of the invention.

[0073] Although the invention has been described in detail, nevertheless changes and 5 modifications, which do not depart from the teachings of the present invention, will be evident to those skilled in the art. Such changes and modifications are deemed to come within the purview of the present invention and the appended claims.

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Claims

CLAIMS What is claimed is:

1. A method of manufacturing a three-dimensional (3D) puzzle including multiple 3D puzzle-pieces, said method comprising:

5 receiving a 3D object model;

determining division contours of puzzle-pieces of said 3D object model;

creating a piece-model associated with each of the puzzle-pieces, said 3D piece-model is a 3d model of the respective puzzle-piece or a of a mould of the respective puzzle-piece, according to graphical features of the object model and said division 10 contours, wherein said receiving, determining and calculating are carried out by using at least one graphical software tool, which enables outputting 3D piece-model data of each respective puzzle-piece of said 3D puzzle;

receiving each respective said 3D piece-model data; and creating each puzzle-piece of said 3D puzzle separately, according to each 15 received respective said 3D piece-model data, using at least one computer-aided production machinery.

2. The method according to claim 1, wherein said 3D piece-model data comprises commands for allowing said production machinery to create the respective 3D puzzle-piece or a respective 3d mould of each said respective 3D puzzle-piece thereby.

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3. The method according to claim 1, wherein said 3D puzzle is a relief puzzle including a 3D embossment over at least one side thereof.

4. The method according to claim 1 further comprising creating said 3D object model, using said graphical software tool.

5. The method according to claim 3, wherein said creating of said 3D object model 25 comprises:

receiving a two-dimensional (2D) picture; and converting the received 2D picture into a 3D object model, using said graphical software tool.

6. The method according to claim 1, wherein said piece-models are created by using a 30 first graphical software tool enabling modeling and creation of piece-model data file of each respective piece model is carried out using another graphic software tool enabling receiving each respective piece-model and creating a corresponding data file including

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machine commands for allowing said production machinery to read said commands and produce each said respective puzzle-piece thereby.

7. The method according to claim 1, wherein said determining of division contours is carried out manually by a user selecting curvature lines over at least one side of said object

5 model, using designated contour-defining tools of said graphical software tool.

8. The method according to claim 1, wherein said determining of division contours is carried out automatically by said graphical software tool, according to a predefined program enabling both the contour definition and the calculating of the 3D piece-models of said 3D puzzle.

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9. The method according to claim 8, wherein said automatic determining of division contours is carried out by receiving a number of puzzle-pieces and defining a virtual grid over one side of said 3D object model, according to the number of puzzle-pieces and dimensions of the side of said 3D object model.

10. The method according to claim 1, wherein said 3D piece-model is a model of a 15 mould of the respective puzzle-piece, said method comprising:

creating a mould of each respective puzzle-piece from said 3D piece-model of the respective mould; and creating each respective puzzle piece by using said respective puzzle-piece mould.

11. The method according to claim 1, wherein said creation of each respective puzzle-20 piece comprises:

first creating each respective puzzle-piece using a 3D model of the puzzle piece itself;

then using each of said 3D puzzle-piece to create moulds therefrom; and mass producing each respective puzzle-piece from the puzzle-pieces' moulds, using 25 at least one injection-technique.

12. A system for manufacturing a three-dimensional (3D) puzzle including multiple 3D puzzle-pieces, said system comprising:

a computer system including a first module, which receives a 3D object model,

allows determining division contours of 3D pieces of a 3D puzzle of said object 30 model and creates a 3D piece-model associated with each of the puzzle-pieces,

according to graphical features the 3D object model and said division contours, and outputs or stores 3D piece-model data of each respective puzzle-piece of said 3D

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puzzle, said 3D piece-model is a 3D model of a respective puzzle-piece or a mould of a respective puzzle-piece; and at least one computer-aided production machinery, which enables receiving 3D piece-model data of each puzzle-piece and producing a respective said 5 corresponding 3D puzzle-piece according to said piece-model data, wherein each 3D puzzle-piece is created separately

13. The system according to claim 10 wherein said computer-aided production machinery comprises at least one of: a milling machine; a 3D printer; an electro-discharge machining; laser-based production machinery.

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14. The system according to claim 12, wherein said milling machine is a computer numerical control (CNC) milling machine, which enables receiving computer commands and operate at least one milling cutter automatically, according to received commands, wherein said piece-model data comprises commands adapted for said respective milling machine.

15 15. The system according to claim 12 wherein said production machinery comprises at least one milling machine and at least one moulding machine for casting moulding materials into a predefined mould, wherein said mould is created using said milling machine.

16. The system according to claim 12 further comprising a second module for creating 20 piece-models' data files from said 3D piece models, wherein said second module receives said 3D piece models of said 3D object model from said first module and converts each such 3d piece-model into a data file that includes said machine commands.

17. The system according to claim 10 wherein said graphical software tool enables receiving a two-dimensional (2D) picture and converting said 2D picture into a 3D object

25 model.

18. The system according to claim 12, wherein said first module further allows a user to select a number of puzzle-pieces and automatically determine the contour lines of the respective 3D object model by determining a grid defining said division contours, according to the selected number and according to dimensions of said 3D object model.

30 19. The system according to claim 12, wherein said first module further enables determining surface textures of said 3D puzzle and said production machinery allows creating said surface textures accordingly.

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20. The system according to claim 10, wherein said computer system is embedded in said production machinery allowing receiving 3D piece models and automatically producing them.

21. The system according to claim 12, wherein said production machinery comprises a 5 3D printer.

22. A three-dimensional (3D) puzzle comprising a multiplicity of 3D puzzle-pieces, wherein said puzzle is produced by receiving a 3D object model; determining division contours of puzzle-pieces of said 3D object model; creating apiece-model of each of the puzzle-pieces, according to graphical features of the object model 10 and said division contours, wherein said receiving, determining and calculating are carried out, using at least one graphical software tool, which enables outputting 3D piece-model data of each respective puzzle-piece of said 3D puzzle, said 3D piece-model data comprises commands data for allowing at least one production machinery to create 3D piece models of said 3D puzzle thereby, and 15 wherein each said respective 3D puzzle-piece is created separately, according to each received respective said 3D piece-model data, using said production machinery.

23. The 3D puzzle according to claim 22, wherein said puzzle is a relief puzzle.

24. The 3D puzzle according to claim 22 further comprising at least one support 20 member for supporting at least some of said puzzle pieces once joined to one another.

25. The 3D puzzle according to claim 24, wherein said support member includes at least one of: a supporting board, a support pole.

26. The 3d Puzzle according to claim 25, wherein said supporting board 25 comprises protrusions or sockets that interlock with corresponding sockets or protrusions of their respective puzzle-pieces A

27. A relief puzzle comprising a multiplicity of relief puzzle-pieces,

wherein said relief puzzle is produced by receiving a puzzle object model;

determining division contours of puzzle-pieces of said object model; creating a

30 piece-model of each of the puzzle-pieces, according to graphical features of the object model and said division contours, wherein said receiving, determining and calculating are carried out, using at least one graphical software tool, which enables outputting 3D piece-model data of each respective puzzle-piece of said relief

puzzle, said 3D piece-model data comprises commands data for allowing at least one production machinery to create 3D piece models of said relief puzzle thereby, and wherein each said respective puzzle-piece is created separately, according to each received respective said 3D piece-model data, using said production 5 machinery.

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