Project:Jigsaw Puzzles

ProjectInfoBox Jigsaw Puzzles
Status:	work in progress
Release Date:	2025-02-19
Initiator:	B--rian
Materials Used:	4mm poplar plywood, e.g. [ (no affiliation)
Tools Used:	Laser Cutter
Software Used:	Gimp, Inkscape, Lasercutter-Software
Approx. Cost:	Up to now: A4 poplar sheets 3,45€ machine running donnation: 0,80€

Puzzles Examples

Isn't that what comes to mind first, when getting started with laser cutting wood?

• https://wiki.comakingspace.de/File:B--rian_HeidelbergCastle_Jigsaw.svg

Recipe

The following recipe is not complete yet!

Image Preparation

1. Select and Prepare the Image: Choose a high-resolution color image for your puzzle. Adjust the brightness, contrast, and saturation using photo editing software.
2. Dither the image.
3. Designing the puzzle pieces using a tool like ...
4. Using a vector graphics tool like Inkscape, check the outline for your puzzle.

Preparation for Machining

1. We have to ensure that all the puzzle piece lines are recognized by the laser cutter as cutting paths.
2. Choose a laser-friendly material such as plywood or acrylic, see [Materials].
3. Set the laser cutter parameters (speed and power) according to the material being used, usually provided by the laser cutter's manual.

Get physical

1. Start up the water cooler.
2. Switch on the laser cutter.
3. Send the design from the laser cutter software to the machine by hitting the "Download" button.
4. Secure the material onto the laser cutter bed.
5. With open laser cutter lid, hit Start which will simulate the actual cutting. The red positioning laser allows you to check, whether you will stay on your piece of material.
6. If everything looks ok, close the lid, and go for it! Monitor the laser cutter during operation to ensure nothing catched fire.

Learnings and remarks

Thomas Eddison supposedly once said I never once failed at making a light bulb. I just found out 999 ways not to make one.. The same is true for laser cutting jigsaw -- most likely things will not immediately work, so here a few things I learned so far:

Two common failures when laser cutting jigsaw-puzzles: If you don't put anything underneath the workpiece, puzzle pieces may just slip through the knife bed into the collection tray. The result are pieces which are being incorrectly (purple ellipses) cut since they are tilted, or only cut partially (purple rectangle).

• Don't make the puzzle pieces to small, otherwise the knobs of the puzzle pieces may easily break.
• Stop the laser immediately, if the plywood dissappears unexpectedly through the surface grid into the waste bin drawer.
• Make sure that the engraved picture is not too dark.

Nota bene: This is WIP (work in progress), so please be a bit patient with me. --B--rian (talk) 2025, February 20th