Welcome to Shantou Charmer Toys & Gifts Co.,Ltd. Let’s see how the cardboard turns into a puzzle.
● Printing
After finalization and typesetting of the design file, we will print the patterns on the white cardboard for the surface layer (and print for the bottom layer if needed). They will be coated with a layer of protective oil after printing to prevent abrasion and scratches in the next process, or be laminated with glossy/matte film as customer’s requirement.
● Lamination
We can see that the cross section of the puzzle is very thick paper fiber, which is a gray board layer. When the printing surface is almost dry, the gray board will be laminated with the front and back two layers cardboard. The principle refers to sandwich biscuits. :)
PS: Considering the different needs, the middle layer of puzzles will also be high gram heavy white cardboard paper, so that the puzzle will look more beautiful and not too heavy, which is very suitable for children to play with.
● Special cutting mold
Different from other ordinary die cutting molds, the jigsaw puzzle cutting molds are special. In a grid mold, small pieces will be filled with a layer of elastic latex (or high-density sponge), and its height is generally flush with the cutter point.Because the number of puzzle pieces is large and dense, if you use a conventional mold for die-cutting, you can imagine that the cut puzzle pieces will be embedded in the knives, increasing the difficulty of cleaning. Elastic latex can solve this problem well. It can spring back the puzzle pieces after cutting.
● 2 molds for cutting
Unless it is a jigsaw puzzle with a small number of pieces, this kind of 1000 pieces of jigsaw puzzle usually need 2 molds for cutting: one for horizontal and the other for vertical. If only use 1 mold for cutting, there may be a problem for insufficient pressure and can not cut through all the pieces.
● Breaking up and packing
After cutting, the whole piece jigsaw puzzle will be sent to a breaking up machine and come out into pieces. They will drop in the bag at the end of the machine and be packed with boxes.Go through this step and inspection, the puzzle will be ready for sale or delivery.
Post time: May-30-2023
