- Design: The first step is to design the puzzle, which includes choosing the image to be used, determining the number and size of puzzle pieces, and creating a template or blueprint for the puzzle.
- Printing: Once the design is finalized, the image is printed onto paper or cardstock. This printed image will serve as the guide for cutting the wooden puzzle pieces.
- Mounting: The printed image is then mounted onto a thin sheet of wood, typically made from plywood or MDF (medium-density fiberboard). The wood is then cut into individual puzzle pieces using a laser cutting machine or a saw.
- Sanding: After the pieces are cut, they are sanded to ensure that they have smooth edges and are free of any rough spots or splinters.
- Sorting: The pieces are then sorted and placed into bags or boxes, according to their shape and size. This is typically done by hand.
- Packaging: Finally, the puzzle pieces are packaged, typically in a box made from the same type of wood used to make the puzzle pieces. The box is often adorned with the same image as the puzzle, and may include a picture of the completed puzzle as a reference for the puzzler.
Overall, the production process of wooden jigsaw puzzles requires a combination of skilled craftsmanship and modern technology to create a high-quality product that is both aesthetically pleasing and enjoyable to solve.