Hey, I recieved my second shapeways puzzle and there is a flaw. The puzzle, master quartet, uses a tongue-and-groove mechanism. The first time I made it, I uploaded the pieces seperately because I didn't know better. This time, I uploaded the whole assembly and saved $50 but I noticed a piece that was supposed to be circular wasn't. Could it be possible that since it is a larger file overall, it is being printed in a larger, less exact, printer? The "circlular holes" are flat at the top.. See picture below. On the left is the first type; right, second. Well atleast in real life it's a less-drastic, but I still had to sand down the bottom of the pieces that fit into the groove so they would be flush during the equator turn. A circular file would've worked even better.

Can you take a picture of the actual flawed parts with something in the picture to provide a size comparison? Big flaws are pretty rare. If those holes are only 1mm in diameter or so I could see the flaw you describe as being somewhat likely.

Here's a video http://www.youtube.com/watch?v=nJrmYQsJ ... e=youtu.be

I know for sure it isn't a tolerance problem because the small corned went into to large one perfectly

Yeah that looks totally normal and should be mostly resolve itself during the break-in process.

There is a thin layer of nylon powder that isn't fully sintered / bonded to the rest of the part that comes off during break-in. Usually when you wear down this thin layer to the solid part minor issues like what you've shown go away.

For what it's worth, about 24 hours in a vibratory tumbler with coarse grit takes this outer powder shell off and the puzzle is as good as "broken in". All the rest of the time in the tumbler is just polishing for visual effect.

ok, Thanks!