Summary

Print out 4 identical pieces to assemble a perfect 60mm sphere!

Snapping the 4th piece in its place may be a bit tricky at first, but once secured the whole ball will keep itself assembled until taken apart on purpose.

That was my goal for the design and I reached it with quite a bit of trial and error:
Finding a balance between the piece thickness (2.3mm) and gap between the pieces (0.4mm).

Print Settings

Printer Brand:

Printrbot

                                            <p class="detail-setting printer"><strong>Printer: </strong>                     <div><p>Printrbot Simple Metal</p></div></p>                                                                                <p class="detail-setting rafts"><strong>Rafts: </strong>                     <div><p>Yes</p></div></p>                                                                                <p class="detail-setting supports"><strong>Supports: </strong>                     <div><p>Yes</p></div></p>

Post-Printing

when using a less accurate printer some sanding in the "puzzle cut" area will probably be needed to remove extra material that makes interlocking difficult.

In order to achieve a nice smooth ball, assemble a complete ball and sand all 4 pieces together.

Puzzle Ball (4 piece)