Double-Sided Maze

Project Requirements

Materials Provided:

  • (1) 5″ x 5″ x 1.5″ wooden block (from 2″x6″ lumber)

  • (1) Steel ball bearing

  • (2) Acrylic covers (1/8″ thick, 6″ x 6″)

  • (4) M5 end-cap screws and M5 nuts (distributed in Woodshop)

  • Note: Wood is stocked in the Woodshop. Acrylic is stocked in Fab Lab South.

Click on each section below to learn about this project. Happy building!

LED Acrylic Display

Step 1: Preparing the Wooden Blank

Prepare a block measuring:
– Width: 5″
– Length: 5″
– Thickness: 1.5″
Cut to size using the table saw or miter saw.

Step 2: Drilling Mounting Holes

Create four mounting holes to attach the acrylic covers later.

– Use the drill press
– Drill through-holes positioned ~1/4″ from each corner for M5 (using ¼” drill bit)
– Ensure alignment as these holes must later align with the acrylic covers and hardware.

Step 3: Designing the Maze in CAD (CNC Job)

Create a double-sided maze for CNC routing.

Cutter

CAD procedure (for the wood piece):
– Start with a 5″ x 5″ x 1.5″ solid block
– Extrude cut maze pattern on top face (depth ~0.5″)
– Route width should fit a 5mm bearing ball.
– Extrude cut maze pattern on bottom face (depth ~0.5″)
– Make one continuous hole from top to bottom maze so the ball can move between sides
– Export final design as a STEP (.step) file.

Step 4: Making Acrylic Covers (Laser Job)

Two acrylic covers will enclose the maze.
CAD requirements (acrylic pieces):
– Start with the 6″ x 6″ x 1/8″ plate
– Create a 5″ x 5″ centered window area
– Add mounting holes located 1/4″ from each corner (same pattern as wood block)
– Holes must align across: acrylic -> wood -> acrylic
– Export as a DXF or Illustrator file for laser cutting.
– Bring the file to Fab Lab South, and a TA will help you to laser cut it.

Step 5: CNC Routing the Wood Block

Machine the maze pattern using the CNC router.

Procedure:
– Bring STEP file to Woodshop
– TA will assist with toolpaths and routing
– Machine both maze faces to ~0.5″ depth

Step 6: Finishing the Maze Block

Lightly sand surfaces and edges
– Remove debris from channels for smooth rolling
– Verify ball motion and pathway continuity

Step 7: Final Assembly

Order of assembly:
1. Place the ball inside the maze
2. Position the wood block between the two acrylic covers
3. Align all corner holes (critical!)
4. Insert M5 end-cap screws through acrylic → wood → acrylic
5. Secure with M5 nuts
6. Confirm the enclosure is tight and the ball rolls smoothly

Step 8: Testing and play!

Tilt and navigate the ball through both maze sides.