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Demand for jigsaw puzzles saw a surge, comparable to that of the Great Depression , during the COVID pandemic stay at home orders  .
Most modern jigsaw puzzles are made out of paperboard since they are easier and cheaper to mass-produce than the original wooden models.
An enlarged photograph or printed reproduction of a painting or other two-dimensional artwork is glued onto the cardboard before cutting.
This board is then fed into a press. The press forces a set of hardened steel blades of the desired shape through the board until it is fully cut.
This procedure is similar to making shaped cookies with a cookie cutter. The forces involved, however, are tremendously greater and a typical piece puzzle requires a press that can generate upwards of tons of force to push the knives of the puzzle die through the board.
A puzzle die is a flat board, often made from plywood, which has slots cut or burned in the same shape as the knives that are used.
These knives are set into the slots and covered in a compressible material, typically foam rubber, which serves to eject the cut puzzle pieces.
Beginning in the s, jigsaw puzzles were cut using large hydraulic presses which now cost in the hundreds of thousands of dollars.
The cuts gave a very snug fit, but the cost limited jigsaw puzzle manufacture only to large corporations. Recent roller press design achieve the same effect, at a lower cost.
New technology has enabled laser-cutting of wooden or acrylic jigsaw puzzles. The advantage of cutting with a laser is that the puzzle can be custom cut into any size, any shape, with any size or any number of pieces.
Many museums have laser cut acrylic puzzles made of some of their more important pieces of art so that children visiting the museum can see the original piece and then assemble a jigsaw puzzle of the image that is also in the same shape as the piece of art.
Acrylic is used because the pieces are very durable, waterproof, and can withstand continued use without the image fading, or the pieces wearing out, or becoming frayed.
Also, because the print and cut patterns are computer-based, lost pieces can be manufactured without remaking the entire puzzle.
By the early s, Tower Press was the world's largest maker of jigsaw puzzles, acquired by Waddingtons in In addition to large-scale puzzle manufacturers, numerous puzzle makers work in an artisanal style, handcrafting and handcutting jigsaw puzzles.
Jigsaw puzzles come in a variety of sizes. Among those targeted to adults, , , and piece puzzles are considered "smaller". More sophisticated, but still common, jigsaw puzzles come in sizes of 1,, 1,, 2,, 3,, 4,, 5,, 6,, 7,, 8,, 9,, 13,, 18,, 24,, 32, and 40, pieces.
Jigsaw puzzles that are geared towards children may have many fewer pieces, typically much larger. For very young children, a puzzle with as few as 4 to 9 "large"-size pieces so not a choking hazard are common.
These are usually made of wood or plastic, to maintain durability, and are able to be cleaned without being damaged. The most common layout for a thousand-piece puzzle is 38 pieces by 27 pieces, for a total count of 1, pieces.
This new-meets-old concept brings cooperative online multiplayer to a gaming tradition that people have enjoyed for centuries.
The history of jigsaw puzzles dates back as early as the 16th century, where cartographer John Spilsbury of London first created them out of wood.
They were originally intended to be used as a learning aid for teaching geography and national boundaries on maps.