3D letter based toys

Inspired by WordWorld where words come alive, the basic concept is that words create the thing that they represent. Thus a dog is created and shaped by the letters D-O-G. Every object in that world is made up, literally, from the letters that name it.

I propose designing such toys that are made up of the letters that make them. Thus, for example, a car will be made up of the letters C-A-R. The challenge here is two-fold: (i) designing toys from the letters, which is relatively easy and (ii) designing the letters to fit several toys. Thus, for example, C should be part of both C-A-T and C-A-R, yet still have a single shape for both.

Hence, I propose an automatic designing algorithm that receives a list of 3D-models of toys, or at-least their 3D-silhouettes, and the letters that make them up. The output of the algorithm is a 3D design of the letters and their attachment, such that one can create the toys simply be attaching the letters together.

The real challenge will be when presented with many toys, such that each letter appears at least twice or thrice. Then a single design of the letter should be the output of the algorithm, such that all the toys can be made. This is a truly constrained problem that should prove to be a challenge to 3D-designers. The reward would be cool educational toys that can be 3D printed by everybody. Good luck.