FILEBOX Puzzle

This is a really unique burr puzzle designed by Yavuz Demirhan who has given permission to distribute for personal enjoyment. I modelled it in fusion 360 to give it some character related to its name Filebox. The idea is that there are two file folders (or plates) in the filebox, and your task is either to:

1. take the 3 documents (burrs) out of the file folders (easier task)
2. put all 3 documents into the file folders (harder)

Because the filebox comes apart, you don't need any extra software or a solution to put this puzzle together. Full instructions on making and assembling filebox are in the video below.

Normally, with a caged burr puzzle, one takes the puzzle apart and cannot put it together. The straps on both ends is a unique feature in filebox because it allows easy assembly without requiring a solution. This also gives the puzzle two levels of difficulty.

Harder: Place the plates inside the filebox cage so the A and B labels align with the corresponding tabs on the file folder (plates). Attach the straps to hold the top and bottom parts of the filebox together. Now try to put the 3 documents (burrs) into the filebox.

Easier: With the file folders (plates) outside the filebox, insert the 3 documents thru the plates. Now place everything in the bottom of the filebox. Attach the top with the straps and you have a nice take-apart puzzle.  

Printing

I printed all parts in PLA except the straps which should be PETG. PETG will flex much more than PLA and is more suitable for holding the top and bottom together. I've used them up to 20 times with no breakage.

The general settings are 0.2mm layer, 3 walls, 4 perimeters top/bottom.

Nothing except the 3 burrs requires support. 

Because I wanted strong burrs, I printed them as one part. This means they require support, but I wanted the middle beam to have accurate dimensions. So I put a circle on the top of the beam, made the underside 0.3mm narrower, and used a red Sharpie to paint onto the support just before the first layer of the beam. I also set the support to zero distance. The Sharpie ink acts as a release agent and you can see by the picture, that the underside came out nice and did not require any sanding. Because of the zero support distance, you don't get any drooping. If you use a BLACK sharpie, the ink can/will transfer to your beam. Use the painted-on support option and leave a gap at the ends, so you can easily paint the support structure without getting ink on the ends. Pictures above show how I set up the support and the result. I used the filament change option in Prusa slicer to pause the print at the correct layer. You need to actually change the filament as well.. but this was the easiest way for me to pause the print at the correct spot. My 3MF file has this set up for you.

If you use the 'sharpie" technique, do one burr first to test. 

The video below has an introduction to the filebox puzzle and shows how the pieces should move. The assembly section shows how the parts go together. I've also included some info on the designer, followed by a peek at the FileBox2 sequel puzzle. If you have any interest in building that, put a note in the comments.

Solution

I encourage you to spend much time learning about the unique design of the puzzle. But if you wish a solution, it is provided in this video.