JIGSAW PUZZLE WAS MADE BY A JIGSAW
A jigsaw—though it’s also called a scroll saw. If you’ve never seen one, a scroll saw has a fine, straight blade that’s usually mounted vertically a little bit like the needle in a sewing machine. By running the blade up and down (hooray, power tools) and moving wood through it, you can cut fine patterns into wood. Note that the term “jigsaw” can also refer to a coping saw, which is a handheld power tool with a straight blade sticking out—great for cutting holes in walls, but perhaps not puzzles.
So that’s great. But how do people make jigsaw puzzles today?
The short answer is: It’s complicated. There are still high-end handmade puzzles on the market today, but commercial makers have typically moved on to other methods. Below, let’s examine the most popular methods.
Mass-produced commercial jigsaw puzzles are made of cardboard. Nobody hand-cuts cardboard with a jigsaw. So the game is all about making a cutting die (a sharp metal outline) that emulates that jigsaw cut. Once you have a cutting die, it can be used to stamp out countless cardboard puzzles.
The metal template allows safety-gloved employees to snap in the edges of each piece, allowing for a unique pattern for each puzzle design.
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