Making a Jigsaw Puzzle: How Are Puzzles Made?

Ever wonder how puzzles are made? Thanks to modern laser-cut technology, the process is not nearly as taxing as the original wooden puzzles of the 18th century. No sawing necessary for these jigsaws.

The Puzzle Making Process

We start with a paperboard backing of what is essentially a poster of the puzzle design. It goes into the cutting machine and is punched through (like a cookie cutter does to cookie dough). The puzzle comes through fully cut but still connected. 

Where’s the fun in that? Never fear; we know you like the challenge.

The cut puzzle slides onto another belt for the pieces to be broken apart and separated. The puzzle pieces are then sifted through a machine that shoots the pieces into a bag, which is then pressed and sealed. 

Next Step: Packing

First, the reference sheet is added to the corresponding puzzle box, which accompanies a special message from team Blue Kazoo, alongside the sealed bag of puzzle pieces. The lid is then added and the box is placed in shrink wrap, which enters another machine (heated this time) to tighten and seal the shrink wrap. 

And that’s it! The puzzle is now ready to be shipped and delivered to its new home. Like our puzzles, we craft the boxes with quality design in mind. You know how good it would look on your shelf. 😉

Need a visual? Here is a 60-second video of Abraham walking through the process of creating our Mars puzzle. 

@bluekazoogames Ever wonder how jigsaw puzzles are made? Take a tour, hosted by @Abraham Piper 🧩 #jigsaw #puzzle #puzzles #jigsawpuzzle #puzzletok ♬ Lofi - Domknowz

What Are Jigsaw Puzzles?

If you got this far and are still wondering what a jigsaw puzzle is, let's take you through a quick history of puzzles.

We'll start with who invented puzzles: John Spilsbury. Spilsbury was a cartographer who had the brilliant idea of creating puzzles, then known as "dissected maps" in 1760. Puzzles at that time were wooden maps broken up into sections to teach students geography.

These puzzles evolved and transitioned from wooden carvings to paperboard backing, allowing them to be mass-produced. Designs were no longer limited to school subjects and soon art, scenery, and even products were utilized.

Unlike the early creations, the pieces of jigsaw puzzles became more seamless as technology advanced, crafting interlocking puzzles that linked without any gaps.

More than just a teaching device, puzzles are now a beloved activity that can bring a piece of mind (see what we did there? 😏) during even the busiest of times.