Custom jigsaw puzzle manufacture
Turn your photos and ideas into the perfect Jigsaw Puzzles
Most custom puzzles break apart because of the little things, like sloppy die-cuts that won’t snap, boards that start to flex in the middle of a run, or print registration that progressively drifts out of alignment. A sample could look great, but those problems show out when a lot of them are put together.
At Funway, we don’t simply care about how the artwork looks on a screen; we also care about how the pieces fit together and how stable the board is. We make puzzles that not only appear like art, but also last on the table. Whether you’re making a promotional run or starting a high-end retail line, we have the puzzles for you.
We Provide All options for Custom Jigsaw Puzzles
Custom Jigsaw Puzzles Sizes & PCS
We manufacture everything from high-volume small sets to 2,000-piece collector puzzles. Using our existing die library is the fastest way to get moving—it eliminates tooling fees and keeps your per-unit cost down.
- Standard MOQ: Starts at 500 sets per SKU.
- Custom Tooling: If our standard sizes don’t fit your vision, we can build custom dies for any shape or non-standard dimension you need.
The combinations below are our “off-the-shelf” options (meaning the dies are already in our warehouse). If you need a specialty board or a unique footprint that you don’t see here, just let us know—we do full custom builds every day.
Small Jigsaw Puzzles (Kids & Entry-Level)
These need to be fast and foolproof. We prioritize a clean “snap” so kids aren’t struggling with stuck pieces. The goal here is high-speed consistency—no frayed edges, just crisp separation from the first box to the ten-thousandth.
| 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. This is the industry sweet spot for a reason. It’s where you get the best price-to-detail ratio for gift sets. We use a high-density board that can take high-res ink without the paper grain fighting back. It’s a solid, reliable build that doesn’t blow the budget.
| 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)
At 1,000+ pieces, standard board just ‘smiles’ (warps) as soon as the humidity shifts. To prevent that, we use a heavy, cross-grained stock that actually stays flat. No flimsy pieces or lifting corners—it sits flush on the table and stays that way.
| 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
A puzzle’s quality comes down to the sandwich: the core board and the face stock. This combo dictates everything—how crisp the pieces snap together, whether the colors pop, and if the final product stays flat or starts to warp six months later.
Puzzle Core Board Options
The core board is everything. Forget about thickness for a second—what actually matters is the internal bond. If the board is “mushy,” the pieces won’t snap, no matter how thick they are. You want a core that’s stiff enough to hold a clean edge; otherwise, the whole puzzle just feels like a stack of loose coasters.
high-density grey board
High-density greyboard is the industry standard for a reason—it’s tough, reliable, and keeps the budget in check. We run 1.5mm to 2.5mm depending on the scale. The rule of thumb: as your piece count goes up, your board thickness has to follow, or you’ll end up with a flimsy mess that won’t stay flat.
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.” “Blue core is for the ‘snap’ enthusiasts. It’s much denser and tougher than greyboard, which means zero bending at the piece level. We usually run this in 1.8mm to 2.2mm for premium retail lines.
white core board
White core is the ‘cleanest’ look—perfect for kids’ puzzles where safety and a bright, upscale finish are the priority. It’s not just about aesthetics; it’s a positioning move for brands that want to stand out from the standard greyboard crowd.
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.
When image quality is the top priority—especially for gallery-grade or high-end export sets—we swap the duplex board for 128gsm or 157gsm art paper. It’s a thinner, tighter surface that holds ink much better, giving you sharp details and deep colors that standard stocks just can’t hit. We typically pair this with a matte lamination or varnish; it kills the glare from indoor lights and gives the puzzle that smooth, ‘luxury’ feel collectors expect.
Custom Jigsaw Puzzle Shapes & Die-Cutting Options
Shape dictates your production economics. It’s not just about the look—it’s about sheet yield, tooling complexity, and box dimensions. Standard formats are built for speed and zero waste, while specialty shapes are an investment in ‘shelf pop’ and brand identity. 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
Shape dictates your production economics. It’s not just about the look—it’s about sheet yield, tooling complexity, and box dimensions. Standard formats are built for speed and zero waste, while specialty shapes are an investment in ‘shelf pop’ and brand identity.
Round Puzzles
Round puzzles are a design statement, but they require a tighter eye on the layout. Since they don’t fill a rectangular sheet, we have to optimize the ‘nesting’ and box inserts to prevent piece shifting. They’re the go-to for museum gifts and premium souvenirs where the silhouette is the main selling point.
Heart Puzzles
Heart Puzzles: The Shape is the Concept. These are high-impact specialty items for seasonal launches—Valentine’s Day or wedding souvenirs—where the silhouette does all the heavy lifting for the branding.
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.
Offset Printing for Jigsaw Puzzles
Jigsaw puzzles are not just printed and cut. The print has to stay visually stable after the sheet is die-cut into hundreds or thousands of interlocking pieces. That is why offset printing remains the practical standard for puzzle production: it holds color more consistently across the full image and gives better control over print-to-die registration.
- More reliable color continuity across the full puzzle image
- Better retention of fine artwork, thin lines, and soft gradients after die-cutting
- Tighter print-to-die alignment, which helps keep piece edges cleaner and the image break points less distracting
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
Finishing is your final defense against glare and wear. It’s what dictates the ‘hand-feel’ and determines if the puzzle survives a 1,000-piece scramble without scuffing. You’re balancing three things here: tactile quality, long-term durability,+B16:B21 and your production budget.
Matte Varnish
Matte Varnish is the ‘stealth’ option. Since it’s a liquid wash rather than a film, it adds zero thickness—this is crucial for maintaining tight die-cut tolerances and a perfect piece fit. It’s the most cost-effective way to kill reflections on high-volume runs without changing the physical profile of the board.
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 is the collector’s favorite. The cross-hatch texture doesn’t just kill glare; it adds a tactile friction that makes pieces easier to grip. The real win: it hides the ‘battle scars.’ Tiny scratches from sliding pieces around just get lost in the grain, so the art stays clean even after the puzzle’s been assembled a dozen times.
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 is the heavy-duty choice. Unlike varnish, this is a physical film that bonds to the board, offering the best protection against moisture and ‘edge break’ during die-cutting. It gives the artwork a deep, velvet-like saturation and a premium heft that you just can’t get with a liquid coating.
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
Manufacturing specs change depending on the job. You can’t build a mass-market promo the same way you build a 1,000-piece art set. We don’t use a standard template; we adjust the board density and cutting tolerances for each project to make sure the final product handles exactly right for its specific market.
- Tabletop Publishers & Game Brands: For games that live or die by the artwork, we prioritize zero-drift registration and ‘clean snap’ piece separation. We make sure complex illustrations line up perfectly across the cut lines so the gameplay experience never feels cheap.
- Retail Puzzle Production for Brands and Merchandising Programs: We support retail-ready puzzle production with material, box, and packing decisions based on real shelf, shipping, and handling requirements. The structure needs to work not only for presentation, but also for piece protection, repeat opening, and standard retail distribution.
- 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 a better fit for weddings, parties, and branded events where the puzzle is meant to be kept as a keepsake, not used as a throwaway giveaway.
We provide scalable manufacturing solutions for wedding planning groups and gift distributors, supporting standardized template customization for seasonal inventory requirements.
Landscape & Art Puzzles
Landscape and art puzzles leave very little room for printing error. In this category, even minor color shift, weak gradients, or surface glare can damage the image quickly, especially in skies, water, shadows, and detailed artwork. What matters here is keeping the image clean after production, not just getting it printed. The color needs to stay controlled, the detail needs to stay sharp, and the finish cannot interfere with the artwork itself.
Educational & Institutional Puzzles
Educational puzzles are usually expected to survive more repeated handling than standard retail gift puzzles. In this category, board durability, clean die-cut edges, and practical material safety matter more than decorative finishing. These projects are commonly developed for schools, museums, classroom use, and supervised learning programs where durability and consistent handling are more important than premium visual effects.
Kids & Family Gift Puzzles
Kids and family puzzles have to be straightforward to handle and quick to sort, otherwise the puzzle stops feeling enjoyable very early. That usually means larger piece formats, reliable interlock consistency, and board strength that can better tolerate repeated use. For gift and family-oriented retail programs, the structure has to work for both presentation and real play, not just for shelf appearance.
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
