Crafting Jigsaw Puzzles: Unveiling the Puzzle-Making Process

Have you ever wondered about the intricate process behind creating jigsaw puzzles? Thankfully, with the advent of laser-cut technology, producing puzzles has become far less laborious compared to the wooden puzzles of the 18th century.

We’ve talked about the puzzle-making process in a previous blog post, but we’ve made some significant upgrades with our new sustainable jigsaw puzzles in how we make and package them.

The journey begins much the same way with a paperboard backing that serves as the canvas for the puzzle's design. The difference here is we’ve upgraded our paperboard backing to 2MM thick blackboard for an extra snug fit. The backing is fed into a cutting machine, where it is punched out, much like a cookie cutter shapes dough. The result is a puzzle that is cut but still intact. 

I Heart Tetris jigsaw puzzle | Blue Kazoo

Where's the fun in leaving it like that, though? The cut puzzle moves onto another belt, allowing the pieces to be broken apart and separated. The puzzle pieces then pass through a machine that propels them into the compostable bag, which is then sealed.

Next comes the packing phase. The premium reference sheet is placed inside the corresponding puzzle box. Next, the sealed compostable bag containing the puzzle pieces is included. The lid is then affixed to the box, and the entire package is sealed off with biodegradable stickers. We’ve ditched the cellophane shrink wrap previously used to package our puzzles for this eco-friendly alternative. 

Curious as to what the jigsaw puzzle-making process looks like? Check out this quick video:


And there you have it! This fully biodegradable puzzle is now ready to embark on its journey to its new home. Just like our meticulously crafted puzzles, we ensure that the puzzle boxes are designed with the utmost quality in mind. Imagine how stunning it will look displayed on your shelf!

Understanding Jigsaw Puzzles: A Brief Historical Insight

If you've made it this far and still find yourself wondering what exactly constitutes a jigsaw puzzle, allow us to take you on a quick historical exploration. Jigsaws originated in 1760, when cartographer John Spilsbury introduced puzzles as educational tools, employing wooden maps divided into sections to teach geography to students. Over time, puzzles evolved, transitioning from wooden carvings to utilizing paperboard backing, enabling mass production. As a result, puzzle designs expanded beyond academic subjects to encompass art, scenic landscapes, and even everyday objects.

With advancing technology, the construction of jigsaw puzzle pieces became increasingly seamless. Interlocking mechanisms were developed, creating puzzles that fit together without any discernible gaps. Don’t believe us? Try the lift test the next time you finish a puzzle. When you’re done, glue your puzzle together and frame it for a gorgeous piece of wall art.