The first step in our jigsaw puzzle production process is to search the world for images rich in color, composition, perspective, passion, and hutzpah. Once we find or create an image, we produce a Giclee print of it with archival ink on archival paper using a state-of-the-art, wide-format printer. We dry-mount it onto five-ply, Finland-grade Birch, and laminate it for UV, fingerprint, and moisture protection with a laminate that also makes the image shimmer in the sun. I then cut it into hundreds of tricky pieces using a high-end scroll saw and dozens of very thin saw blades that break every ten minutes or so. Finally, the puzzle is assembled, the back is sanded and branded with the Berkshire Puzzle Co. name, and it is packaged with tissue paper and a title sticker that gives an indication of the size and difficulty of the puzzle.
I cut in various styles, all of which are free-form and spontaneous. Color lines are always a major design factor, but other factors such as cut style, spacing, and interestingness of the pieces have a strong impact in the cut choices as well. I try to make each puzzle a clever, cohesive collective of individually interesting, attractive pieces. I am particular about the figurals I include in our puzzles, as their wonderful, endearing element is offset by the greater ease in the assembly of the puzzle. In general, I choose the figurals I cut in puzzles to match the puzzle's primary theme, and I include zero or one figurals in the 8"x8" puzzles, two in the 10"x10"s and up to four in the 12"x12"s.
In addition to our Gallery Puzzles, we offer custom puzzle cutting. I will cut a puzzle out of your digital photograph or image, and you can request specific figurals in your puzzle for special occasions, such as a bride and groom ballroom-dancing for a wedding puzzle, hearts for a Valentine's Day puzzle, or different types of dogs, leaves, birds, farm animals, wild animals, etc., for an everyday puzzle. Keep in mind that each figural makes the puzzle much easier to put together.
We also offer a unique custom event package for special events such as weddings, first birthdays, Bar Mitzvahs, 75th birthdays, 50th anniversaries, etc. You can find out more about this package and about our Gallery Puzzles at our Puzzle Store .