The Jigsaw Manufacturing Process

We print our jigsaws using the latest print technology which enables us to print both small and large quantities to the same outstanding quality. Our jigsaws have a beautiful silk finish, giving optimum sheen without the glare of a high gloss finish, which can can impair visibility when completing a jigsaw. Unlike a matt finish, our silk effect has a smooth touch, allowing puzzlers to run their hand across the finished puzzle – what we refer to as ’the jigsaw rub’!

Key Facts

  • 1000 piece jigsaw measures 69 x 48cm
  • 500 piece jigsaw measures 48 x 34.5cm
  • Supplied in a high quality 33 x 20 x 5cm box with barcode
  • Branding & full colour print to all sides
  • Free design service
  • Unique lustre finish
  • Bonded onto 1.75mm luxury recycled board
  • Royal Mail Small Parcel dimensions
  • Short runs of only 10 units!
  • Exceptional customer service
How to Order
Once printed, the images are bonded to 1.75mm blue puzzle board made of recycled paper based material. This is a precise process, how the puzzle is glued effects the crop and ultimate puzzle cut. Our gluing machine works within a 0.5mm tolerance, allowing us to be extremely accurate. No hand gluing can be so precise. After gluing, the puzzles are tumbled and left to cure to allow all the moisture to leave the board.
Once completely set, the puzzles are then individually trimmed on our Platen press to the size of the finished jigsaw. They then go onto our hydraulic jigsaw cutting press, where our uniquely created jigsaw die cuts the jigsaw with 420 tonnes of pressure. This sleek process is hand fed by experienced operators who constantly quality check.
Our dies are created by local company Crosland cutters. We work closely with their design team to produce a bespoke die which offers the customer variation in piece shape. Once cut our jigsaws travel along a conveyor belt to be scrambled and fed into an automatic bagging machine. After this they are placed into their boxes, ready for the end user.