Fusion Overload is a themed 3D Printed puzzle where you must open the container to prevent overload and access the contents within.

THIS DOWNLOAD IS FOR THE DIGITAL 3D PRINTABLE MODEL ONLY

Please be warned, it is VERY challenging to print, and your 3D printer must have a perfect first layer and be capable of clearing 0.3mm gaps on the clearance gauge at a minimum.

The model is error free and slices well - despite some warnings in Prusa Slicer.

This model is designed to be printed on FDM/FFF 3D Printers and was tested on an ender 3.

In addition to the printed model, you will need:

1 x 1/2" Steel Ball
1 x 6x6mm neodymium magnet cylinder.

PLA Recommended
0.15mm Layer Heights
3 Perimeters
4 Bottom, 5 Top Solid Layers
15% Cubic Infill (or similar)

NO Supports
NO Brim

Raft CAN be used if your first layer isn't perfect, but not recommended due to additional cleanup.

Print in place instructions:

Print Fusion Overload Nested Bodies.stl separately to Fusion Overload Base.stl and ideally in different colours.

Around two hours into the printing of Fusion Overload Nested Bodies.stl you will be able to place the 1/2" ball bearing into the model at the beginning point as highlighted in the attached image. The print takes roughly 24hrs to complete, so you have plenty of time to catch it. Don't place it too early or it may collide with the hot end! 

When the print reaches the 80mm mark it is a good time to insert your treasure/prize into the chamber. It can be anything you like, but keep in mind it will get fairly warm a few hours as the print bridges over the top and encases it! You must also allow room for the ball bearing to eventually escape into the center chamber, highlighted in the images attached.

Once printed, carefully remove from the print bed. There should be slight movement between each body indicating they're not fused. If there's resistance you can try a firm tap on a hard surface, but if your printer has left stringing or blobs between the two parts they may never come free... hence the need for that 0.3mm clearance!

Attach Fusion Overload Base.stl to the puzzle with a firm, slight twisting motion and the puzzle is complete! 

OPERATING THE PUZZLE:

This puzzle will only open once the 1/2" ball bearing has found its way into the central chamber. It's tricky because it moves unseen in unpredictable ways and the path twists back on itself often. To make it even more challenging, the puzzle can partly open at many points due to the balls location, but will never fully open. DO NOT FORCE the base, or it may snap off. Excessive force is not a solution to this puzzle.

If you can open the chamber without any additional assistance, I am shocked! Well done. However, if you get stuck that's where the magnet key comes in! 

A strong neodymium magnet helps you "feel" for the ball and navigate the hidden path easier.

I have also experimented with printing in clear or translucent PLA which can help under good light, I don't think it looks very good but is another option.