Jigsaw Puzzle - Construction

Construction

Most modern jigsaw puzzles are made out of cardboard, since they are easier and cheaper to mass produce than the original wooden models. An enlarged photograph or printed reproduction of a painting or other two-dimensional artwork is glued onto the cardboard before cutting. This board is then fed into a press. The press forces a set of hardened steel blades of the desired shape through the board until it is fully cut. This procedure is similar to making shaped cookies with a cookie cutter. The forces involved, however, are tremendously greater and a typical 1000-piece puzzle requires a press that can generate upwards of 700 tons of force to push the knives of the puzzle die through the board. A puzzle die comprises a flat board, often made from plywood, which has slots cut or burned in the same shape as the knives that are used. These knives are set into the slots and covered in a compressible material, typically foam rubber, which serves to eject the cut puzzle pieces.

Beginning in the 1930s, jigsaw puzzles were cut using large hydraulic presses which now cost in the hundreds of thousands of dollars. The cuts gave a very snug fit, but the cost limited jigsaw puzzle manufacture only to large corporations. Recent roller press design achieve the same effect, at a lower cost.

New technology has enabled laser-cutting of wooden jigsaw puzzles, which is a growing segment of the high-end jigsaw puzzle market.