How to Make a Puzzle

Co-authored by Ryaan Tuttle

Last Updated: May 16, 2022 Approved

Putting a puzzle together is a fun activity and a great workout for your brain. Making your own puzzle is even more fun, and adds a whole new dimension to the activity! Homemade puzzles also make heartfelt gifts that you can customize and personalize for the unique people in your life. Depending on the tools you have at your disposal, you can make a more traditional jigsaw puzzle from wood, or you can make a simpler puzzle with cardboard. Either way, friends and family will love putting together your handcrafted puzzles!

1

Choose Your Design

You can print a photograph to use for your puzzle image, draw or create your own, or even use a card, poster, or any other printed image. For a photograph, choose a high-resolution image, and size it based on how large you want your puzzle to be. Print it off or have it developed at a photo lab according to your specifications. For a hand-drawn puzzle image, choose a high-quality paper that’s the size you want your puzzle to be. Using your favorite medium, draw or paint your image directly onto the paper.
- You can also create your own puzzle image on a computer, and then print it off like a photograph.

2

Assemble Your Tools

You will need glue, spray lacquer, a ruler, and a pencil. For a cardboard-backed puzzle, you will need sharp scissors or a hobby knife. For a wood-backed puzzle, you will need either a coping saw^{[1]
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- Liquid craft glue or spray glue will work best for your puzzle because it’s multi-purpose and won’t damage photographs.
- If you are using a photograph for your puzzle image, be sure to find lacquer that’s safe for it.
- You can even use a Dremel tool.^{[3]
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- It has a variety of blades and attachments.
- It is suitable for cutting and making little notches.

3

Select a Puzzle Backing

Plywood is more durable and traditional, but this will only work if you have a saw at your disposal and are confident in your skill with that tool. Cutting out a puzzle is delicate work and requires experience. You can also use a good quality cardboard to back your puzzle. This will be much easier to work with, and can be cut with scissors. Craft-quality cardboard can be found at most craft stores.
- The ideal thickness for a puzzle backing, be it cardboard or plywood, is one-eighth inch (0.3 cm).^{[4]
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- Look for a piece of backing that’s as close to the size of your puzzle image as possible to avoid waste.
- You can use the cardboard from on old box to back your puzzle, but make sure it’s clean, undamaged, and flat. Thin cardboard like that from a cereal box will work for a simple puzzle, but thicker cardboard is preferable.

4

Attach Your Image

Place your backing on a sheet of wax or parchment paper to protect the surface underneath. Place it good side down. Spray or cover the surface of the backing with glue and spread it around so there’s an even coat all over it. Place your picture onto the backing. Use your fingers to slide it around so it’s centered and straight. With a roller or old credit card, apply even pressure to the picture to help the glue adhere and remove bubbles.^{[5]
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- Let the glue dry. Glues have different drying times, but give your puzzle several hours to set if possible.

5

Lacquer Your Image

Take your puzzle outside or to a well-ventilated area. Place it back on the parchment or wax paper. Spray an even coat of lacquer over the image. Check the can for drying time, and allow it to dry.

6

Trim Your Border

If your puzzle image is smaller than the backing, begin by trimming down the edges of the backing. For a cardboard puzzle, use your scissors or place your puzzle face up on a cutting mat and use your hobby knife. For a wood puzzle, use your saw to carefully trim the border so that the backing is the exact shape and size as the puzzle image.
- With a hand saw, place most of the puzzle on a solid, flat surface (like a table) with the side you want to cut overhanging the edge. Firmly hold the puzzle with one hand to keep it in place and use your other hand to hold the saw and cut.

7

Create a Grid

Flip your puzzle over and place it image-side down. Use a ruler to mark out and draw a grid pattern made up of squares that are three-quarters of an inch (for a puzzle with more, smaller pieces) or one inch (for a puzzle with fewer, larger pieces).
- Instead of drawing your own puzzle template, you can print off templates from sites like Tim’s Printables.

8

Draw Your Template

To create puzzle pieces, begin adding ball and socket shapes (concave and convex half-circles) along the edges of the grid squares so that the pieces will fit into each other when the puzzle is cut.^{[6]
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Research source} You can also use inverted and protruding triangles, squares, or other shapes.
- For pre-drawn puzzle templates that you’ve printed off, glue them on to the back of the puzzle and allow it to dry.^{[7]
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9

Cut out Your Pieces

For cardboard puzzles, follow the puzzle piece template you’ve drawn on the back and use your scissors to cut out the pieces. Or, if you’re using a utility knife, put your puzzle face down on your cutting mat and carefully cut the pieces. Or, cut out the pieces with your saw, being careful not to cut yourself. When you have finished, use an eraser to remove any remaining pencil marks.
- To make it easier, don’t cut out pieces individually. Rather, cut entire rows or columns at a time, and then go back and cut out the individual pieces.^{[8]
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- The lacquer will help protect the image from damage as you’re cutting out the pieces, and this is especially important if you’re using a saw.

Community Q&A

Question

How do you cut round edges?

Community Answer

The easiest way to cut round edges is to use a very precise X-acto knife. In a pinch, any small, sharp blade will work, including paring knives or box cutters. You can also use the eraser of a small, round object, like a pencil or pen, to provide a guide.
Question

How can I make my cut edges smoother?

Community Answer

Over time, your cutting knife will become dull, and will result in ragged edges on your puzzle pieces. Try changing your blade out for a new one every now and then. If you still get ragged edges, try sanding them lightly with some fine grit sandpaper.
Question

What is lacquer? Do I have to use it?

Community Answer

Lacquer is a type of clear sealant. You don't have to use it. You can use any thing you want (as long as it's clear and good quality), like gloss or even clear nail polish.

Warnings

For young puzzle makers, ask your parents for assistance, and don't cut anything without supervision.

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Always use caution and proper equipment when using cutting tools and saws. Take the proper safety precautions to protect yourself and others. Never put your fingers in front of a blade.

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If you don’t have the skills or experience to cut your own puzzle, ask for some help from someone who does!

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