Sizes & Piece Counts
Choose a standard format, or tell us your own size. Piece count, piece size and board thickness work together, so the bigger the puzzle, the firmer the board should be.
Standard formats
Mini puzzles
- 150 × 100 mm5.9 × 3.9 in150 pcs
- 210 × 180 mm8.3 × 7.1 in24 pcs
- 200 × 480 mm7.9 × 18.9 in160 pcs
Small gift puzzles
- 263.5 × 231.7 mm10.4 × 9.1 in24 / 48 / 100 / 150 pcs
- 350 × 254 mm13.8 × 10 in24 pcs
- 346 × 480 mm13.6 × 18.9 in12 pcs
Medium retail puzzles
- 381 × 285 mm15 × 11.2 in24 / 48 / 100 / 150 pcs
- 420 × 420 mm16.5 × 16.5 in49 pcs
- 430 × 430 mm16.9 × 16.9 in500 pcs
Panoramic & special formats
- 850 × 320 mm33.5 × 12.6 in200 pcs
- 1000 × 275 mm39.4 × 10.8 in1000 pcs
- 680 × 490 mmSpecial shape1000 pcs
- 520 × 380 mmAssorted-piece layout500 pcs
Large puzzles
- 520 × 380 mm20.5 × 15 in500 pcs
- 600 × 420 mm23.6 × 16.5 in49 pcs
- 610 × 610 mm24 × 24 in1000 pcs
- 680 × 490 mm26.8 × 19.3 in912 / 1000 pcs
- 685 × 508 mm27 × 20 in1000 pcs
- 700 × 500 mm27.6 × 19.7 in1000 pcs
Need another size or a custom die-cut shape? Tell us your dimensions and we will set up the tooling.
Which piece count fits your audience?
12 – 100 pieces
Kids & floor puzzles
Large, easy-to-grip pieces. Thicker board and rounded corners suit young hands.
24 – 200 pieces
Gift & promotional
Compact, postcard or travel formats for brand giveaways, events and gift sets.
500 – 1,000 pieces
Retail & art puzzles
The core of the adult market. Pieces average about 2.2 cm at 500 and 1.9 cm at 1,000.
1,000 – 2,000+ pieces
Collector & large format
Premium editions and display puzzles, where fit, board stiffness and print quality matter most.
Board & Materials
The board decides how a puzzle feels, snaps together and lasts. Choose by print quality, edge finish and budget.
Duplex grey board
- Lower cost
- Good interlocking grip
- Keep in mind
- Edges are rougher, with a risk of fuzzy edges and paper dust. The grey base can dull light-colored artwork.
White core board
- Excellent print quality on a high-contrast white base
- Better color reproduction than other boards
- Durable, from 700 to 2500 gsm
- Keep in mind
- The layered structure is clearly visible at the cut edge.
Blue core board
- Supports high-precision die cutting
- Smooth edges with few burrs
- A better feel in the hand
- Keep in mind
- Higher cost.
Black core board
- Suits artwork with a black main color
- Best for black backgrounds
- Keep in mind
- Higher cost. We recommend it for puzzles with a black background or a mostly black design.
Different thicknesses, such as 1.5 mm, 2 mm and 2.5 mm, can all be customized. Tell us your idea.
Printing & Finishing
Printing method sets your minimum order and unit cost. The surface finish sets how the puzzle looks under room light and feels in the hand.
Printing method
Offset printing
From 500 sets. Full-color CMYK on coated paper, with high resolution and consistent color across larger runs. It suits retail and art editions.
Digital printing
From 100 sets. Full-color CMYK without plates. Good for small batches, test runs and quick promotional puzzles.
Surface finish
Glossy lamination
High-shine film that deepens colors and protects the surface.
Soft-touch film
Smooth, velvety film with a quiet, premium feel.
Matte lamination
Low-glare film with a refined, understated look.
Holographic glitter
Laser-style film with glitter that shifts under the light.
Foil stamping
Metallic foil pressed onto selected areas of the artwork.
Velvet
Soft, suede-like surface that feels warm and rich.
Glitter
Fine glitter particles for a sparkling surface.
Glow-in-the-dark
Luminous areas that glow in low light.
Linen texture
Lightly embossed linen grain with a tactile, anti-glare feel.
Flocking
Fine fibers applied for a plush, velvet-like touch.
Cloth texture
Fabric-like grain with a woven look and a soft grip.
UV coating
Glossy UV over the whole surface or on selected areas, for depth, contrast and highlights.
Lamination is applied before cutting, so the finish protects the printed surface through repeated handling and assembly. Wipeable, moisture-resistant and anti-glare coatings are also available.
Precision die cutting
- Custom die tooling for any size or contour
- Tight cutting tolerances for clean edges and even assembly
- A pre-production sample lets you test how pieces interlock
Inserts & Packaging
The box is the first thing a customer sees, and the inserts are what they find inside. Choose both to match how the puzzle is sold.
Box types
Standard tuck box
Folding carton with a tuck closure. Economical and retail-ready.
Lid-and-bottom box
Two-piece rigid box with a separate lid, strong on the shelf and in the hand.
Magnetic rigid box
Flip-top rigid box with a magnetic closure for a keepsake unboxing.
Tin box
A metal tin that doubles as reusable storage.
Add-ons
Printed sleeve Wrap band Shrink wrapping Barcode labeling Inner bag for loose pieces
Box artwork is placed on a dieline matched to your puzzle size. Explore custom box options.
Instructions & inserts
Reference poster
A printed copy of the finished image, so puzzlers can check their progress as they build.
Assembly leaflet
A single-fold or accordion-fold guide with sorting tips and help for special shapes.
Booklet
A stitched booklet for artist notes, the story behind the artwork, or multi-language instructions.
Thank-you card
A small printed insert for your brand message, care tips, social links or a discount code.
- Full-color CMYK printing
- Custom size, layout and page count
- Coated or book paper options
See all formats on our Booklets & Instructions page.
