HISTORY OF JIGSAW PUZZLES

While working on my WIP, set in 1878, I wondered if my character could do jigsaw puzzles, so I googled the history of jigsaw puzzles and was surprised by what I found. I thought others might find it as interesting as I did.

Anand cartographer, John Spilsbury, of London, is believed to have produced the first jigsaw puzzle around 1760, using a marquetry saw. Early jigsaws, known as dissections, were produced by mounting maps on sheets of hardwood and cutting along national boundaries, creating a puzzle useful for the teaching of geography. Such "dissected maps", were used to teach the children of King George III and Queen Charlotte by royal governess Lady Charlotte Finch^.
engraver

The name "jigsaw" came to be associated with the puzzle around 1880 when fretsaws became the tool of choice for cutting the shapes. Since fretsaws are distinct from jigsaws, the name appears to be a misnomer. Cardboard jigsaw puzzles appeared during the late 1800s, but were slow to replace the wooden jigsaw due to the manufacturer's belief that cardboard puzzles would be perceived as being of low quality, and the fact that profit margins on wooden jigsaws were larger.

Jigsaw puzzles soared in popularity during the Great Depression, as they provided a cheap, long-lasting, recyclable form of entertainment. It was around this time that jigsaws evolved to become more complex and more appealing to adults. They were also given away in product promotions, and used in advertising, with customers completing an image of the product being promoted.


Sales of wooden jigsaw puzzles fell after World War II as improved wages led to price increases, while at the same time improvements in manufacturing processes made cardboard jigsaws more attractive^.
According to the Alzheimer Society of Canada, doing jigsaw puzzles is one of many activities that can help keep the brain active and may contribute to reducing the risk of developing Alzheimer's disease.

Modern construction

Most modern jigsaw puzzles are made out of cardboard 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 1000-piece puzzle requires a press that can generate upwards of 700 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 1930s, 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 achieves the same effect, at a lower cost^..By the early 1960s, Tower Press was the world's largest maker of jigsaw puzzles, acquired by in 1969.

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.