Consider packing puzzles based on circles (discs) instead of (say) squares.
For a virtual puzzle, the way circles kiss at random angles has a very different feel than squares orthogonally flush against each other. For a physical puzzle, circles eliminate the complexity of having to rotate the object to the correct angle.
One can also consider a physical puzzle of spheres (balls). Pack them into a large hemisphere with a flat lid that closes flush if you've solved it correctly. Gravity matters in 3D.
The discs and balls and containers may be of different sizes, but let them be of "discrete" sizes to facilitate independent virtual investigation (i.e., write a computer program): circles of area integer multiples of pi, again reminiscent of squaring the square. Radii square roots of integers, permitting finer gradation than integer radii as well as possibly elegant Pythagorean calculations.
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