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  1. #5
    Does the package allow for rounding external corners to match the inevitable rounded internal corners?

    It all reminds me of this, again based on deformed hexagons but with no symmetry (although in that case the guy took a very roundabout route to generate his gcode). Both designs are necessarily a bit wasteful as you cannot cut the interlocked figures and you just have to try to fit them on the material as best you can. I recreated this latter design from scratch to use for sets of coasters which will then interlock across a table-top. The design in this thread would work quite well for the same kinds of things.

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