At The Jigstore, we believe every puzzle tells a story. But have you ever wondered how your favourite premium jigsaw puzzle comes to life? From the first sketch to the final piece, here’s a peek behind the scenes at the craftsmanship and care that goes into creating a truly premium puzzling experience.
1. It Starts with Stunning Artwork
Every great puzzle begins with a compelling image. Whether it’s a breathtaking landscape, a whimsical illustration, or a vibrant collage, choosing the right artwork is key. Our premium puzzle brands work with talented artists and photographers from around the world to curate images that are not only beautiful but also engaging to piece together.
2. Design and Layout
Once the artwork is selected, it’s time for the design team to step in. The image is carefully formatted and adjusted to fit the dimensions of the puzzle. Designers also consider how the image will translate into pieces—ensuring a balance of colours, textures, and visual interest across the entire puzzle.
3. Cutting Dies are Created
For premium puzzles, custom cutting dies are designed and manufactured. These are essentially cookie-cutter-like tools made of steel that stamp out the puzzle pieces. The pattern of the die influences the uniqueness and challenge of the puzzle, with some brands even using unique piece shapes for extra difficulty.
4. High-Quality Printing
The selected artwork is printed onto paper using fade-resistant inks. Premium puzzles often use a linen-textured finish to reduce glare and enhance the tactile experience.
5. Mounting onto Puzzle Board
The printed sheets are then glued onto durable, recycled cardboard. The mounted images are then set aside for several days while the glue cures.
6. Precision Cutting & Bagging
Once printed and mounted to the puzzle board, the image is cut in a cutting press using the custom die. This process requires extreme precision to ensure clean edges and perfect interlocking pieces. The pieces are then broken up and bagged.
7. Quality Check
Each puzzle goes through a quality check to make sure all pieces are accounted for, the printing is flawless, and the cuts are clean. In many premium brands, this process is partially done by hand to ensure an exceptional final product.
8. Beautiful Packaging
The finished puzzle is then boxed with care. Premium packaging often includes sturdy boxes, resealable bags, and a full-size image poster to reference while puzzling. The design of the box itself is often treated as an extension of the puzzle art.
From Studio to Tabletop
Take a look at the complete journey with this video from Ravensburger Puzzles: