How To Make Jigsaw Puzzles

Written by Charles Peacock
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If you've ever wondered why jigsaw puzzles are called jigsaw puzzles, the answer is pretty simple: they used to be made using jigsaws. In the old days, puzzle makers would use a thin jigsaw to cut the shapes out of a flat piece of wood. These days, jigsaw puzzles are rarely made using actual jigsaws. Let's take a look at some of the modern manufacturing methods.

How Jigsaw Puzzles Are Made

If you want to make your own jigsaw puzzle, the best method is probably to go the traditional route and use an actual jigsaw and a thin piece of wood. If you're looking for a good, complex puzzle, however, it's best to leave the dirty work to the experts. Hundreds of interlocking pieces are hard to achieve if you're cutting by hand!

Most of the puzzles on the market today are cardboard puzzles that are produced using the same method: mass-production die cutting. This process involves a cutting die that features a blade bent into the shape of the puzzle cuts. The die is pressed onto a solid piece of cardboard, which is then instantly cut into the pre-determined shapes.

Today, you can buy high-end wooden puzzles that are designed and manufactured using a far more advanced (and high quality) production process. This process incorporates computer design and laser cutting techniques to produce delicate, complex puzzles that have the look and feel of handcrafted, old-fashioned puzzles. The advantage of using computers is that the process can be sped up substantially, meaning the puzzles are affordable despite their level of complexity.


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