How Puzzles are Made

For centuries, people have found joy in assembling jigsaw puzzles. While modern puzzle making is a highly mechanized process, it remains an intricate blend of artistry and precision craftsmanship. From the initial selection and treatment of the image to the meticulous design of each unique piece, every puzzle is a testament to the dedicated effort of those involved in its creation. As you embark on your next puzzle challenge, consider the fascinating journey that went into crafting it.

Artwork Selection and Processing

The puzzle-making journey begins with the selection of the artwork for the image. This critical first step involves choosing or commissioning an image. Options are vast, ranging from vibrant scenic landscapes, renowned works of art, captivating photographs, to custom hand-drawn or computer-generated designs. The design team thoroughly discusses potential images before making a final selection.

Once chosen, the artwork undergoes digital enhancement using computer-aided design (CAD) software. This ensures the image is of the highest possible resolution, crucial for maintaining clarity when enlarged. Brightness, contrast, and color are meticulously adjusted, and the image is precisely scaled to the desired puzzle size. The design team and editors then conduct a final review, making any necessary adjustments, down to the tiniest detail, to guarantee perfection.

Material Preparation and Design

With the final artwork approved, attention turns to the physical components:

Raw Materials

1. • Puzzle Board: The foundation of any puzzle is its puzzle board, typically a high-quality chipboard made from a composite of paper and specialized adhesives. The board's thickness, weight, and density are carefully chosen as they directly impact the durability and tactile "feel" of the finished puzzle pieces.

   • Lithographs: The chosen, high-resolution image is printed onto lithographic paper using the lithography method. This paper is specifically selected for its vibrant color reproduction and superior print quality.

   • Adhesives: Crucial for bonding the image to the board, these adhesives must be strong enough to withstand the intense cutting process and repeated assembly, yet flexible enough to allow for a snug, satisfying fit of the pieces.

Designing the Cut Pattern

This is where the puzzle's unique personality begins to appear. 

1. • Cut Pattern: Using specialized computer software, a cut pattern is meticulously designed. This digital template dictates the precise shape and interlock of every single piece, ensuring both uniqueness and variability throughout the puzzle.

   • Printing the Image and Adhering It to the Board: The image is printed on a lithographic machine and then precisely glued onto the puzzle board. This process requires careful alignment to prevent bubbles or wrinkles. Once adhered, the combined sheet is either air-dried or cured under heat and pressure to create a secure and durable bond between the image and the cardboard

Precision Cutting

The bonded puzzle sheet is now ready for the most distinctive step: cutting. This is a highly mechanized process, but relies on expertly crafted tools:

• • The Die: At the heart of the cutting process is the die. This is a flat, precise template, often crafted from high-grade plywood. Skilled toolmakers painstakingly hand-make, bend, shape, and sharpen hardened steel blades, fitting them into slots in the die board that perfectly mirror the desired puzzle piece shapes. The blades are surrounded by a compressible material, typically specialized rubber, which helps eject the cut pieces once the die lifts. The intricate design of the die determines the unique shape and precise fit of every single puzzle piece.

  • The Die Press: The prepared puzzle sheet is fed into a die-cutting press. This powerful machine exerts tremendous mechanical force—a typical 1,000-piece puzzle requires a press capable of generating upwards of 750 tons—to push the sharp steel blades of the die completely through the board. The immense pressure means the die blades dull quickly, and they can only be re-sharpened once or twice before needing replacement.

Finishing Touches and Distribution

After cutting, the puzzle undergoes several final stages:

• • Quality Check: Each batch of cut puzzles undergoes a rigorous quality check to ensure all pieces are properly separated and meet standards.

  • Separation: The cut jigsaw puzzle is then transferred to a puzzle scattering machine. Here, the pieces are thoroughly broken apart by stirring, shaking, or blasts of air. 

  • Packaging: The loose pieces are then sealed into plastic bags, which are subsequently placed into their boxes. Boxes often include a smaller print of the puzzle image, a box stand, or other supplementary items.

  • Final Quality Check & Shrink-Wrapping: A final quality inspection is performed before the boxes are sealed and shrink-wrapped. The wraping protects the puzzles from moisture and ensures they remain a pristine condition until the box is opened by the customer.

  • Shipping: Finally, the completed and packaged puzzles are stored and then shipped to retailers or directly to individual customers, ready to bring joy and challenge to puzzlers worldwide.

Final Thoughts

The puzzle manufacturing process is interesting. Check out videos on the internet that show how it all happens.