Good luck laukejas !
Wouldn’t have worked without the idea of Dennis Bacon , thank you!
You the man berg_lauritz … Thanks for the acknowledgement. Unfortunately I am not able to check out exactly what you have done since your file is a future version for me, but I do have a good idea of what you did. Your file is a dumb solid for me. I can see you are pretty excited (does that little guy ever stop running back and forth?) about what you came up with as I am also.. Yes, Good luck laukejas This was fun.
Did half the part; mirrored the body (don’t merge); cut both parts individually with a normal cut from the same sketch with the puzzle pattern; moved each of the cut sides back by .5mm with move face & the selection pop-up “internal to feature” (because a thin cut does not have the option to cut “normal to” and offsetting the sketch is too unstable); combined the bodies and voila: