# Constraints and Advice on Maze Parts

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## CyberCut Parts

### Flat Double-Sided Mazes

Stock is 1 inch thick, acceptable area about 12x12 inches.

Noah:
Use 3/8" endmill to cut 3/8" wide paths with 1/4" walls between them.
Cut path 3/8" deep (leaving 1/4" mid-bottom thickness).
Make through holes also with 3/8" diameters.

Suggested layout:
18x18 grid points for the channels and 1/2" border around it.
It probably would look nice, if the through holes are predefined in pleasing manner, for instance all grid points u,v where (u mod 3 = 2) AND (v mod 3 =3), i.e. locations 2, 5, 8, 11, 14, 17. The maze algorithm handed out in class would have to be modified so that in these locations the search proceeds through the hole to the other side in a non-random manner.
No special starting and end-points are required; the task could be to roll the ball from any corner to any other corner.
To make the corners more distinct positions, they could be restricted to have access from only ONE direction.

Danyel:
Use 1/2" endmill to cut hexagonal grid of "junction" pockets on hexagonal grid with ideally 0.866" center-to-center spacing, (so that adjacent circles will overlap so that they will leave a channel of 0.25" width.)
Place "connector" pockets of 0.5" diameter at mid-points between junction points -- where desired.
Cut junction and connector pockets 3/8" deep (leaving 1/4" mid-bottom thickness).
Make through holes also with 0.5" diameters.

Suggested layout:
It probably would look nice, if the through holes are predefined in pleasing manner, for instance, so that all through holes are surrounded by six junction pockets that do NOT go through the stock.
Thus if you can fit about 13 junction pockets in a straight line into the available 1 foot work area, then all even positions could be through holes.
As in Noah's case above, corner positions could be made to be "dead-ends" so that they can serve as ready start ot target positions.

### Maze on Brick

The stock for this exercise should be 4" x 4" x 2"thick.

Yan:
Suggested approach:
Limit yourself to a maze that covers 4 faces.
The maze consists of paths that are 3/8" deep and 3/8" wide, separated by 1/8" thick walls.
Reduce the 2" dimension to 15/8" and then fit 4 path widths into this range; the two outermost paths are flush with the stock edges.
Reduce the 4" dimension to 31/8" and then fit 8 path widths into this range; the two outermost paths are flush with the stock edges. The paths along the stock edges are shared paths that belong to both adjacent surfaces.
In the 3rd dimension, leave the stock somewhat larger than 4" so that the piece can be properly clamped during fabrication.

### Control Wheels for Laser Deflection System

Drew:
Bring in a tentative design for a wheel so that we can obtain the thoughts and concerns of the n group.

## SFF Parts

### 3D Maze Path

Jae has a nice 3D path that could make a sculpture or a climbing structure at a large enough scale. However, I am not sure it is worth spending hard money to make such an object, since I have already several "figure-8 knots" that are similar in concept; and this new geometry is not likely to raise any new issues.

However, making its complement, i.e., a HOLLOW path through space is a different issue altogether ! Obviously one could put a box around this structure and then reverse all the faces to have suitable part description -- but there is a problem with actual manufacturing: how does one get the support structures or the un-sintered powder out ? We talked about running thin holes through all the path axes through the whole cube, through which one could then push a long wire to coax the sand out of the passages. This would be an interesting experiment !

To make the maze not too hard to solve, it should probably just be one long winding path; -- or perhaps a contorted "Y-junction", so that one could put the ball into an "input" slot and then get it out from either a "YES" output or from a "NO" output.

Who is going to take on this experiment ?

### Mazes on Spheres and Tori

We have two nice examples of mazes carved into a smooth surfaces.
Mike has a maze on a torus, and
n has a maze on a sphere.
I believe these are in a state where they could be fabricated with almost any of the SFF technologies. They now should be optimized for aesthetic appeal and checked with the analyzer tools and with the STL viewer tool. It is not clear what we can do with these parts other than admire and exhibit them, since I don't see how we can confine a rolling ball to the path on the surface (unless we package the structures in shrink-wrap!).

One modification would be to modify the path profile, so that it has overhanging side walls with just a small slit-opening for a "ceiling". We would need a couple of access points where a ball could be inserted. Such a more complex structure with many overhanging features should probably be done with SLS where the support structure can easily be brushed away.

One other concern with these structures is price. The have relatively large volumes compared to the interesting part, the surface, where all the action is. Fabrication price depends a lot on build time, and thus these two structures would be relatively costly. Perhaps I will try one, if I have a pleasing design and can get a "free" run somewhere ...

Mike:
If you want to take a chance to see the torus being built,
remove the "dividing wall", make a part about 3/4" thick and 3" outer diameter for SFF.

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