Jigsaw puzzles are typically made through a process called die-cutting, where a sharp blade is used to cut the puzzle pieces out of a flat sheet of material. The process begins with the creation of a master image, which is a full-color image that will be used to create the puzzle. The master image is then printed onto a flat sheet of material, such as cardboard or wood, using a special printing process.
Next, a metal die is created that is the same shape as the puzzle pieces. The die is made by cutting the shape of the puzzle pieces into a flat metal plate. The die is then mounted onto a press, and the printed sheet of material is placed on top of it. The press applies pressure to the die, cutting the puzzle pieces out of the sheet of material.
After the puzzle pieces are cut out, they are often sorted by shape or color and placed into bags or containers. The puzzle is then packaged and shipped to stores or online retailers for sale.
Some puzzle manufacturers may use different methods to create the puzzle pieces, such as laser cutting or waterjet cutting, but the general process of creating a jigsaw puzzle is similar regardless of the method used.