Hanukkah Menorah Puzzle

Overview

This project is a custom Hanukkah Menorah Puzzle created for Akim, an organization supporting adults with intellectual and developmental disabilities.The goal was to design a product that would be:

Easy and intuitive to assemble
Durable and visually appealing
Safe for all users, with no sharp edges or complex parts
Simple and cost-efficient to manufacture using a CNC laser cutter
Suitable for small-batch production and holiday sales

The puzzle consists of a laser-cut wooden base holding anodized aluminum candle holders—each representing a menorah flame.To ensure durability and protect the wooden structure, the puzzle is sandwiched between two clear perspex (acrylic) layers, keeping all pieces aligned and preventing wear over time.

A custom wooden box with finger-joint construction and an engraved “חג שמח” menorah artwork completes the product, creating a clean, gift-ready presentation.The entire design emphasizes accessibility, enabling Akim participants to assemble, package, and prepare each unit with confidence and independence.

Key Features

Anodized aluminum candle holders securely embedded in the puzzle
Perspex top and bottom plates protecting and stabilizing the wooden elements
Laser-cut wooden puzzle base designed with oversized tolerances for easy assembly
Custom finger-joint wooden box for storage and presentation
Laser-engraved menorah artwork (“חג שמח”) on the box lid
Safe, smooth edges suitable for all participants
High-contrast color accents for visual appeal
Designed specifically for Akim’s accessible assembly workflow

Challenge

The puzzle needed to be: -Easy to assemble regardless of dexterity or cognitive ability -Structurally durable and safe -Visually appealing for holiday sales -Affordable and repeatable using only laser-cut parts -Able to securely hold real candles using metal inserts -Protected from wear despite frequent handling Balancing accessibility, durability, and visual quality was the primary challenge.

Solution

To solve these challenges: -The puzzle layout was designed with large, forgiving tolerances to ensure that every piece fits effortlessly. -Two perspex protection plates were added to lock the puzzle together, eliminate misalignment, and prevent damage. -Metal candle holders were chosen for safety, heat resistance, and ease of placement. -The box uses a finger-joint design, allowing perfect alignment without fixtures or tools. -All graphics were laser-engraved, creating a professional finish at low production cost. -The final assembly process was simplified so that Akim participants could build and package each unit independently and reliably.