I created this 3d printable interlocking cube puzzle design over the summer, while thinking of ways to make an interesting puzzle that is printable WITHOUT SUPPORTS. It uses a principle I have dubbed 'Toolbox', which brings together a number of puzzles in the same series. I have created these files FOR NON-COMMERCIAL USE ONLY!!!.
My puzzle design has been published on the excellent site http://puzzlewillbeplayed.com/999/Razorbill/
Design and Copyright : Jeremy Rayner (2018).
Solutions 1 / 8 Moves 220.127.116.11.1.1.3
It is printable without needing any support material. It is quite a challenging puzzle to assemble (in a fun way), and takes 3 moves to remove the first piece once assembled. I have tested this puzzle with my Creality CR-10S printer.
Once the pieces have been printed there is a spoilers assembly video here... https://www.youtube.com/watch?v=Jbq2qYP6-F0
Fillamentum Extrafill PLA 1.75mm
You might consider printing just two of the pieces first, and make sure you get a snug, but not too tight fit, before printing all nine pieces. (I recommend the 2 stl pieces called Razorbill-Top-02-6mm-0_06offset.stl and the smaller piece called Razorbill-Burr-02-6_15mm-0_01offset.stl, make sure they are tight but not too tight.)
I used the standard profile in Simplify3d for the CR-10 (even though I have the CR-10S) but with these changes alone... primary layer height of 0.1500mm, 6 top and bottom layers, 3 outlines (for strength), and a speed of 6000.0mm/min (retraction distance 5.00mm)
My print was a little tight to start with, but after a couple of solves it is just perfect.
I have attached an assembly video for the curious, or if you are making this puzzle as a present for someone else to disassemble, but try to steer clear of spoiler videos for puzzles.