A Porsche 911 R in puzzle pieces

When it was first built over 50 years ago, the 911 R represented a milestone in Porsche's history. In 2016, the sports car manufacturer decided to build a second generation of this classic car. This new generation will now be reissued - in miniature.

In collaboration with Porsche, the toy manufacturer Ravensburger is launching a 3D puzzle version of the 911 R.

The engineers from Ravensburg were just as meticulous in their work as their colleagues in Weissach. The very first step in the development process of a 3D puzzle is a feasibility study using a rough model.

This is followed by an initial prototype. Based on this prototype, the technical product development department divides the vehicle into individual puzzle pieces.

All 3D puzzles are manufactured using a patented process that involves injection moulding the pieces, laser-marking the inner side with ID numbers and printing the design on the outer side.

The design and manufacturing process needs to ensure that movement of the pieces during spraying is minimised - especially when curved and bendable puzzle pieces are involved. Keeping the pieces still is essential in order to produce a precisely printed surface and avoid the colour seeping onto the edges of the puzzle pieces. This stage in the puzzle manufacturing process resembles the wind tunnel tests that take place during the development of the real sports car in Weissach.

The 3D puzzle of the 911 R is just the starting point for an extensive collaboration between Porsche and Ravensburger in the coming years. The two long-established companies share a similar ethos in terms of their dedication to their products, their skilful engineering and their exceptionally high quality standards.