Custom jigsaw puzzle manufacture
Turn your photos and ideas into the perfect Jigsaw Puzzles
Custom jigsaw puzzle manufacturing depends on accurate die-cutting, consistent piece fit, stable board lamination, and controlled print-to-cut registration. Funway provides professional custom jigsaw puzzle manufacturing services for publishers, brands, promotional programs, educational projects, and private-label product lines.
Whether you need a compact promotional puzzle or a large-format jigsaw set, we turn your artwork into a production-ready puzzle product with clean piece separation, reliable construction, and packaging integration that supports sampling, retail programs, and mass production.
We Provide All options for Custom Jigsaw Puzzles
Custom Jigsaw Puzzles Sizes & PCS
We offer custom jigsaw puzzle manufacturing across a wide range of piece counts and finished sizes.
Our standardized size and piece count configurations are designed to streamline product development and optimize landed cost.
- Standard MOQ: Starting from 500 pcs per SKU.
- Custom Tooling: Available upon request for custom shapes and non-standard dimensions.
The size and piece count combinations below include standard production options based on existing die tooling. Custom sizes, shapes, and material upgrades are also available upon request.
Small Jigsaw Puzzles (Kids & Entry-Level)
Ideal for educational publishers, licensed IP brands, and promotional buyers looking for entry-level retail sets or lower-complexity puzzle programs.
| PCS | Standard Finished Size | Shape | Typical B2B Applications |
|---|---|---|---|
| 35 | 310 x 230 mm | Rectangle | Toddler &Early Childhood Education |
| 48 | 310 x 230 mm | Rectangle | Kids Learning Kits &School Projects |
| 100 | 380 x 270 mm | Rectangle | Brand Promotional Giveaways &Souvenirs |
| 300 | 520 x 380 mm | Rectangle | Entry-Level Adult Puzzles &Family Puzzle Sets |
Medium Jigsaw Puzzles (Mainstream Retail & Gift Programs)
This range is often the most practical starting point for puzzle publishers, gift brands, promotional programs, and standard retail lines. These sizes strike the perfect balance between image detail and production speed.
| PCS | Standard Finished Size | Shape | Typical B2B Applications |
|---|---|---|---|
| 500 | 610 x 457 mm | Rectangle | Mainstream Retail &Crowdfunding Rewards |
| 500 | 584 mm diameter | Round | Specialty Brand Merchandise |
| 750 | 610 x 457 mm | Rectangle | Premium Gift &Souvenir Market |
| 1000 | 680 x 490 mm | Rectangle | High-Fidelity Adult Puzzles (Standard) |
| 1000 | 675 mm diameter | Round | Collector’s Edition &Limited Runs |
Large Jigsaw Puzzles (Premium Retail & Collector Editions)
Designed for advanced adult retail, art puzzle lines, and collector-focused projects. At this scale, warp control and precision interlocking become more important to maintain flatness, fit consistency, and overall product quality.
| PCS | Standard Finished Size | Shape | Typical B2B Applications |
|---|---|---|---|
| 1500 | 813 x 610 mm | Rectangle | Advanced Hobbyist &Fine Art Editions |
| 2000 | 1000 x 700 mm | Rectangle | Ultimate Collector’s Edition &Large Displays |
Custom Jigsaw Puzzle Material: Core Boards & Face Stocks
Custom jigsaw puzzle material selection is based on two key layers: the core board and the printed face stock. Together, these materials affect puzzle thickness, rigidity, interlocking feel, print presentation, cut cleanliness, and long-term stability in both sampling and mass production.
Puzzle Core Board Options
The core board is the structural foundation of a puzzle, determining the finished product’s thickness, rigidity, piece feel, and interlocking performance.
high-density grey board
For standard custom puzzle production, the most commonly used core board is high-density grey board, the most cost-effective and commercially viable option. Our core boards are made from virgin or high-quality recycled pulp, with a stable density. Common thicknesses are 1.5 mm, 2.0 mm, and 2.5 mm; projects with many pieces typically require a thicker, more stable core board.
blue core board
For more premium puzzle programs, blue core board is often used as an upgraded option. This type of board is widely associated with higher-end EU and US puzzle products because of its very high density, cleaner cut edge, lower puzzle dust, and stronger interlocking “snap.” It also provides better toughness, which helps reduce bending at the piece level. Common thicknesses are usually in the range of 1.8 mm to 2.2 mm.
white core board
White core board has a cleaner and brighter appearance than standard grey core board. This type of board is often used in children’s puzzles or by brands that want a simpler, more upscale look or prioritize safety. In actual production, material selection depends not only on cost but also on the board’s rigidity, cutting quality, feel, and ultimate market positioning.
Surface Paper Options
The surface paper is the printed face layer of the puzzle. It affects color reproduction, surface feel, glare control, and the final appearance after lamination and die-cutting.
For many standard production projects, especially cost-controlled or mass-market programs, factories often use 250 gsm coated duplex board as the printed face stock laminated to the puzzle core. This structure runs more stably in lamination, gives the finished puzzle a heavier overall feel, and helps control material cost. It is commonly used for promotional runs, entry-level retail, and other budget-sensitive commercial projects.
For more quality-focused export projects, art paper is also a common face-layer option, typically in 128 gsm or 157 gsm grades when the production structure supports it. Compared with coated duplex stock, art paper usually provides cleaner color reproduction, finer image detail, and a more refined printed surface. In practical production, it is often paired with matte lamination or matte varnish to reduce glare and improve puzzle usability under indoor lighting.
Custom Jigsaw Puzzle Shapes & Die-Cutting Options
The shape of a jigsaw puzzle affects die-cut layout, material utilization, packaging structure, and tooling cost. In practical manufacturing, standard shapes are more efficient for production, while specialty shapes are better suited for branded and presentation-driven projects. Existing die tooling can often be used for standard formats, while custom shapes usually require dedicated tooling and engineering review.
Rectangle puzzles
Rectangle puzzles are the most widely used format in custom jigsaw puzzle manufacturing. They offer the most efficient paper sheet utilization, the broadest availability of standard die options, and the most practical production logic for packaging and carton planning. Because of this, rectangle puzzles are usually the best starting point for standard retail lines, educational puzzles, art puzzles, promotional programs, and most export-oriented B2B projects.
Square puzzles
Square puzzles provide a more compact and visually balanced format, especially when the artwork has a centered composition or the customer wants a more distinctive shelf presentation without moving to a fully irregular shape. Compared with rectangle puzzles, square puzzles still remain relatively efficient in die-cutting and packaging, while giving the finished product a different retail identity.
Round Puzzles
Round puzzles are a more specialty format and usually require more specific die planning than standard geometric shapes. Because the finished outline does not follow a standard rectangular perimeter, layout efficiency and packaging structure need to be reviewed more carefully during development. Even so, round puzzles offer stronger visual distinction and are often selected for branded gift products, museum and souvenir programs, collector-oriented puzzle lines, novelty retail projects, and presentation-driven promotional campaigns.
Heart Puzzles
Heart-shaped puzzles are typically used for seasonal and themed projects where the shape itself is part of the product concept. Compared with standard formats, they rely more on custom contour die-cutting and tighter border alignment control. This format is commonly used for gift programs, event merchandise, tourism souvenirs, and other presentation-driven retail or promotional projects.
Jigsaw Puzzles Printing & Color
Jigsaw puzzle printing is engineered for color consistency, artwork alignment, and clean separation after die-cutting. Our printing process is calibrated to keep the full image stable across the puzzle before and after cutting.
High-Resolution Offset Printing
All game boards are produced using high-resolution offset printing, optimized All puzzles are produced using high-resolution offset printing, optimized for accurate color reproduction and stable performance during die-cutting.
- Ensures consistent color across the full puzzle image
- Maintains sharp detail for fine artwork and smooth gradients
- Supports precise print-to-die registration for cleaner piece edges
Color profiles are calibrated for each production run to reduce visible color shift between puzzle sections
Registration & Die-Cutting Alignment Control
Printing accuracy must align with die-cutting precision. We control artwork-to-die registration to support clean separation, continuous image flow across connected pieces, and reduced edge chipping or color break along cut lines.
Jigsaw Puzzles Surface Finishing
Surface finishing affects glare control, surface feel, print protection, and how the puzzle performs during assembly, die-cutting, and repeated handling. In practical custom jigsaw puzzle manufacturing, the finishing option should be selected according to artwork style, target market, and the required balance between cost, durability, and surface performance.
Matte Varnish
Matte varnish is a liquid coating applied during the printing process. It dries to a smooth, non-reflective finish that reduces glare while providing a basic layer of protection against light scuffing. Because it is a coating rather than a film, it does not add thickness to the printed surface, which helps maintain more stable die-cutting tolerances and piece fit. Matte varnish is usually the more cost-efficient finishing option for large-volume production where glare control is needed without moving to a laminated structure.
Engineering characteristics:
- Cost-efficient for large-volume production
- No added film thickness on the printed surface
- Reduces glare for a more comfortable assembly experience
Recommended for:
Educational puzzles, children’s puzzles, mass-market retail, and cost-sensitive promotional projects
Linen Finish (Embossed Texture)
Linen finish applies a micro-embossed cross-hatch texture to the surface paper after printing. For jigsaw puzzles, this texture helps reduce glare under typical indoor lighting conditions, gives the surface a more tactile feel, and creates a more refined matte appearance. It can also slightly increase surface friction, making pieces easier to handle during sorting and assembly. In addition, the embossed texture helps mask minor surface scuffs caused by repeated handling.
Engineering characteristics:
- Reduces glare and diffuses harsh reflections under indoor lighting
- Provides a premium, linen-like tactile surface
- Helps mask minor surface scuffs from repeated handling
Recommended for:
Professional retail puzzle lines, fine art puzzles, and premium adult collector editions
Matte Lamination
Matte lamination applies a thin, non-glossy plastic film to the printed paper stock before mounting to the core board. Among the common finishing options, it offers the strongest surface protection against moisture, abrasion, and repeated handling. It also creates a smoother, more premium hand feel and gives the printed image a deeper, more stable appearance with very low glare. In practical puzzle production, matte lamination is often selected when better long-term durability and stronger finished presentation are required.
Engineering characteristics:
- Strong surface protection and improved moisture resistance
- Helps conceal fingerprints and reduce visible surface wear
- Helps reduce edge color break during die-cutting and repeated handling
Recommended for:
High-end boutique puzzles, custom gift products, and premium large-format puzzles (1000+ pieces)
Custom Jigsaw Puzzle Manufacturing
for Retail, Promotional & Educational Applications
Different market sectors require different specifications in materials, die-cutting precision, surface finishing, and packaging structure. At Funway, custom jigsaw puzzle manufacturing is engineered based on the technical and commercial requirements of each application, rather than treated as a one-size-fits-all product.
- Tabletop Publishers & Game Brands: We support puzzle-based game products that require stable print-to-die registration, clean piece separation, and accurate alignment across complex artwork.
- Retail Brands & Merchandising Programs: We provide retail-ready puzzle production with practical material selection, packaging coordination, and board structures suitable for repeated handling in standard retail environments.
- Educational, Museum & Institutional Projects: We support projects that require safer materials, cleaner edge quality, and more controlled product presentation for classroom, museum, and educational use. collector editions.
- Corporate Gifting & Promotional Campaigns: We offer cost-controlled volume production and practical specification planning for branded giveaways, Fortune 500 enterprise promotions, and campaign-based puzzle programs where timing, budget, and consistency all matter.
Below are typical puzzle formats developed for different commercial applications:
Wedding & Party Guestbook Puzzles
This format is usually produced with a stable board structure and writable surface treatment to support cleaner signing performance and a more premium commemorative presentation. It is commonly selected for weddings, parties, brand activations, and other event-based keepsake projects.
We provide scalable manufacturing solutions for wedding planning groups and gift distributors, supporting standardized template customization for seasonal inventory requirements.
Landscape & Art Puzzles
These puzzles rely on controlled color reproduction, fine detail retention, and low-glare surface finishing to preserve natural gradients and complex visual depth. They are commonly used for fine art puzzles, souvenir programs, and premium retail puzzle lines.
Educational & Institutional Puzzles
Thisl puzzles are typically manufactured with safer materials, cleaner cut edges, and more durable board construction to support repeated handling in classrooms, museums, and other supervised learning environments. They are widely used for school projects, institutional programs, and children’s educational products.
Kids & Family Gift Puzzles
This format is usually designed with larger pieces, stronger board support, and reliable die-cut consistency to improve handling and assembly for younger users. It is commonly used for children’s retail puzzles, holiday gift products, and family-oriented promotional programs.
Accessories
Elevate your cards with our selection of fun and playful accessories. These add-ons are the perfect way to enhance the user experience and create a memorable product. Funway offers a range of standard options, and we also love bringing custom ideas to life.
See Puzzle types
Types
- Traditional Puzzles
- Invitation Puzzles
- Mini Puzzles
- Tray Puzzles
- Collage Puzzles
- Double-sided Puzzles
- Kids Puzzles
- Panoramic Puzzles
- Guest Book Puzzles
- Endless Puzzles
- Coloring Puzzles
- Foil Puzzles
- Glow in the Dark Puzzles
- Acrylic Puzzles
- Family Puzzle
- Tube Puzzles
- Cork Puzzles
- Sliding Puzzles
- See more…
Size
- 29.5 x 38.5 inches
- 12 x 36 inches
- 19.25 x 28 inches
- 18.4 x 12 inches
- 18 x 24 inches
- 19 x 19 inches
- 12 x 16.5 inches
- 8 x 10 inches
- 6 x 6 inches
- 3.9 x 5.9 inches
- 5 x 7 inches
- 5 x 5 inches
- 3.5 x 5 inches
- 3 x 4 inches
- 3.1 x 3.9 inches
- Custom requirements?
Shape
- Rectangular Puzzles
- Square Puzzles
- Heart Puzzles
- Round Puzzles
- Number-Shaped Puzzles
- Tree Shaped Puzzles
Accessories
- Puzzle Frames
- Puzzle Boxes
- Metal Stand
- Roll-Up Puzzle Mat
- Crayons
- Puzzle Keyring
- Puzzle Necklace
- Puzzle Sample Pack
- Greeting Cards
- Gift Cards
1,638+
Commercial Projects
who we are
Your ultimate board game manufacturer
Dongguan Funway has been the trusted ODM/OEM expert for brands seeking top-quality custom board games, card games, puzzles, and packaging solutions. We bring creativity to life through integrated one-stop services
Our factory is equipped with over 16,000+ sqm dedicated facility and 200+ skilled team members. We have a ready mold here to meet your specific needs.
Call US
+86 135 7085 3827
