All of Geranium puzzles (mini geranium, pocket geranium, geranium and super geranium)

Summary

Recently I made my mini geranium puzzle. It is very fun to play. The only thing I do not like is it does not look as cool as original Very Puzzle's toys.

I decided to make an acrylic frame. But since I also want to have whole series of Geranium puzzles I ordered laser cutting for all puzzles at once. Fortunately all puzzles use same moving pieces, so no need to design each one specifically.

Here is the result for Mini Geranium and Pocket Geranium. I am still printing higher grade puzzles - Geranium and Super Geranium.
https://www.youtube.com/watch?v=mRKCBltuwPA&feature=youtu.be

Result looks great. Though I have to admit that it feels much heavier than printed one. Moving is somewhat viscous, perhaps due to too smooth piece surfaces that tend to stick. I am working on solution.

I will be glad to see your makes as well as comments on the design

UPDATE 2016-07-26: I finally printed and assembled Geranium puzzle. This time I used slightly different moving parts design - pieces are hollow which reduces area of contact between pieces and frame. This should address viscous movement issue. I also increased some fillets radius so 'corner cutting' should be also improved. See STLs with 'FDM hollow' prefix.

Though I have not played with Geranium yet as I stuck with Pocket Geranium solving.

https://youtu.be/sA4hQ5P4jS4

As for Pocket Geranium. I improved pieces movement as well applying these 2 tricks:

• Sanded back side of the pieces with very rough sanding paper. Thus pieces do not stick to frame so much when using lubricant
• I reduced height of the pieces so that pieces are not too tighten between frame base and glass.

As for pieces height. This seems to be very important for this puzzle that there is enough room for parts to move. I use frame made of 3mm+3mm acrylic glasses, but my parts are just 5.5mm including stickers. This seems to improve moving a lot. I updated all parts with slightly reduced height.

Acrylic frame

Each puzzle frame consists of 4 parts (from back to front)

• Base - solid part, made of 2-3mm thick non-transparent or semi-transparent acrylic
• Frame 1 - a frame with slightly bigger holes (to fit non-visible hooks of moving parts). Made of 3-4mm transparent acrylic
• Frame 2 - a frame with slightly smaller holes. made of 2-3mm semi-transparent acrylic.
• Glass - a part with holes for fingers. made of 2mm or thinner transparent acrylic.

NOTE: Please note that attached pieces are designed for 3mm acrylic for Frame 1 and Frame 2. If you are using other thickness you'll have to re-export STLs from OnShape document. Please refer to 'How I designed this' section for more details.

There are 2 ways to cut these parts. CNC-mill gives little smoother but matt surface. Laser cut surface is transparent but not super smooth. I used laser cut as it looks closer to original puzzle.

Printed moving parts

I designed 2 versions of moving parts: solid parts for FDM printers and hollow for DPL/SLS to save some plastic. I did not tried second option, so I rely on your feedback.

I do not like supports when printing on FDM printer. Instead I split parts into front and back pieces, print them separately and then glue together. This gives much smoother front and back surface.

Table below describe how many pieces you should print for each puzzle