Wood

From forest to finished product. Wooden jigsaw puzzles, unlike their more common cardboard counterparts, are renowned for their durability and heirloom quality, often lasting for generations. If you've ever wondered about the intricate process behind these cherished items, this guide will take you through the detailed steps involved in their creation, from initial concept to the finished product in your hands.

Design Phase

The creation of a wooden jigsaw puzzle begins with meticulous design, encompassing both the visual image and the physical characteristics of the puzzle itself.

• • Artwork Selection: Designers either select existing images or commission new ones. The choice is vast, catering to diverse audiences:

    • For Children: Popular themes often include animals, vehicles, flowers, and characters from current children's films and television shows.

    • For Adults: Options are virtually limitless, ranging from original artistic creations, famous film and music icons, celebrated works of art, and iconic architectural landmarks like the Eiffel Tower.

  • Determining Piece Count: The number of pieces is carefully chosen based on the target audience. Toddler puzzles feature a few large, graspable pieces, while adult puzzles commonly range up to 1,000 pieces or more, offering increasing challenge as skills develop.

  • Designing the Puzzle Shape: Modern wooden puzzles extend far beyond simple rectangles. Designers now create unique overall shapes, including round puzzles, intricate 3D wooden puzzles, and contour-cut puzzles shaped like animals or buildings. These unique outer shapes can significantly increase the puzzle's difficulty by eliminating traditional straight-edged borders.

Printing and Material Preparation

Once the design is finalized, the image is prepared for transfer onto the chosen wood.

• • Wood Selection: The sturdiness and longevity of a wooden puzzle depend heavily on the wood. Common choices include durable hardwoods like birch plywood, walnut, cherry, and maple, ensuring the puzzle withstands years of use.

  • Eco-Friendly Sourcing: Many modern wooden jigsaw puzzle makers prioritize sustainability by using eco-friendly, responsibly sourced wood. Partnerships, such as Robotime's with One Tree Planted, ensure that forests are not depleted, aligning with environmental efforts to preserve trees' vital role in ecosystems.

  • Ink Application: Non-toxic inks are used in the printing process, a crucial consideration, especially for puzzles intended for young children.

  • Printing and Laminating: Images are often printed onto the wood using the lithography method, where a plate transfers the design. After printing, the puzzles are typically laminated to protect the image and then left to dry for several days, ensuring the ink and laminate fully cure before the next stage.

Precision Cutting

Cutting is a precise step that dictates how well the pieces fit together. The method often varies depending on the scale of production:

• • Studio/Small Factory Production: For smaller batches or custom designs, a laser cutter or scroll saw is commonly used. These tools allow for intricate, unique piece shapes and precise cuts.

  • Mass-Produced Puzzles: Larger factories producing wooden puzzles on a mass scale may employ die-cutting. This involves a powerful die-cutting press stamping out pieces with a sharp, flat metal ribbon (die), similar to how cardboard puzzles are cut, but adapted for wood.

  • Piece Size and Complexity: Just as with piece count, the size and intricacy of the cuts vary by target age. Children's puzzles feature large, simple pieces, while adult puzzles, especially challenging ones, will have smaller, more complex, and often unique "whimsy" shapes. Shaped puzzles, which lack straight borders, offer an extra layer of difficulty for experienced adults.

Quality Control

After the puzzles are cut, a vital quality control step ensures that all pieces fit together correctly and that no defects are present. This prevents the frustration of missing pieces or ill-fitting parts for the end user.

Packaging and Distribution

The final stages involve preparing the puzzle for sale and shipment:

• Separation and Boxing: The newly cut wooden puzzle pieces are separated and carefully placed into their packaging. The box always features a clear image of the completed puzzle for reference during assembly.

• Durability Advantage: Unlike flimsy cardboard puzzles prone to damage or loss of pieces, wooden puzzles are inherently sturdy. This durability means they truly "stand the test of time," allowing them to be passed down through generations. While cardboard puzzles are more common, exclusive companies like Robotime continue to produce high-quality wooden puzzles with precision and care, offering a robust and lasting puzzling experience for both children and adults seeking a greater challenge.

Final Thoughts

If basic care is used when working with wood puzzles, they will last for generations.