How Are Puzzles Made?
Jigsaw puzzles are crafted through a detailed process that includes printing the image, cutting the pieces, and packaging the final product. Each step requires precision and expertise to ensure the highest quality.
Printing the Puzzle Image
- Selecting the Image: An image is designed by one of our artists in their favorite medium (painting, hand drawing, computer, etc.) and a final digital image is produced that is high resolution (typically above 300 DPI) to ensure clarity and detail.
- Printing: The image is printed onto high-quality paper using offset printing, a technique that produces vibrant colors and sharp details. This paper is then glued onto a thick cardboard backing using a water-based adhesive.
- Laminating: A UV coating or laminate is applied to protect the image from wear and tear. This step also gives the puzzle a glossy finish, enhancing its visual appeal.
Process of Cutting Puzzle Pieces
- Designing the Die: The die, a metal template with sharp blades shaped like puzzle pieces, is created based on the puzzle's design. This template is crucial for cutting the cardboard into precise pieces.
- Cutting the Pieces: Using a large hydraulic press, the die is pressed onto the cardboard, cutting it into the intricate shapes of a jigsaw puzzle. The pressure must be carefully controlled to ensure clean cuts without damaging the cardboard.
- Quality Control: After cutting, the pieces are inspected. Any pieces that are not cut correctly or have defects are discarded. This ensures that the puzzle pieces fit together perfectly.
Packaging the Puzzle in a Box
- Box Design: The puzzle box is designed to be both sturdy and visually appealing. It typically includes the puzzle image on the box and as an insert, the number of pieces, and other relevant information.
- Filling the Box: The cut puzzle pieces are placed into plastic bags to keep them secure and prevent loss. These bags are then placed into the puzzle box.
- By following these steps, jigsaw puzzles are produced with a focus on quality and durability, ensuring an enjoyable experience for puzzle enthusiasts.
