how to create a giant jigsaw puzzle

How to create a giant jigsaw puzzle

Posted Posted in Artwork, Designers, Exhibitions, How to, Wood

FifeX designs, creates and installs bespoke interactive products, exhibitions and educational resources. They’re based nearby in Tayport. Ken Boyd approached us to help them produce two A2 sized jigsaw puzzles for their customer, REME Museum of Technology. REME wanted to replace two puzzles that were worn out as they had been so well used by visitors.

The museum had two images that they wanted to make into jigsaws. We thought long and hard about the best materials to use and how to cut the pieces accurately, and came up with a plan.

Choosing a material

Firstly, we had to select a material to make the jigsaws from. We settled on 6mm birch plywood because it laser cuts well and wood is a lovely, chunky material to handle. Being pale in colour, the pictures would show up clearly. Also, the wood grain would be visible through the print, a lovely feature. And plywood is robust, chunky and lightweight, very important considerations when the product is designed with younger visitors in mind.

Creating the jigsaw

Once the customer had chosen the material, LaserFlair cut two A2 sized shapes from 6mm plywood and sent them to the printer. They applied the pictures and returned the panels to LaserFlair for cutting into jigsaw pieces.

FifeX found a piece of software for designing jigsaw piece layouts and shapes. It created vector lines that the laser can follow to cut the lines between the pieces. We could select how many pieces we wanted in the x and y axes, and choose regularly or irregularly shaped pieces. We decided on 20 pieces to make each piece the size that the customer wanted, and selected an irregular cutting pattern for more interest. Then we laser cut the puzzle.

The whole process was a great success. This picture shows one of the jigsaws sitting on the laser bed after cutting.

Reclaimed wood laser engraved sign for Old School Fabrications

Can we work with recycled wood?

Posted Posted in Exhibitions, Recycled wood, Signage

I’m often asked if we can engrave recycled wood. Here’s an example of a project where we did just that.

We  laser engraved two of these signs made from reclaimed pine for Old School Fabrications (OSF). They were for an exhibition for the National Library of Scotland in Edinburgh.

When the wood arrived for engraving, it was covered with nasty old green paint and looked awful! OSF had cut the boards to size as they were too thick for us. We just had to engrave them.

Engraving through to the good wood

We made a good, deep engrave to give a significant 3D element to the signs. This was particularly important as OSF wanted to sand the signs after engraving to get back to the good wood under the layers of paint. A pine is a softwood, this was easier to achieve than if oak had been used. Engraving using the same power and speed settings on the laser machine will always deliver a deeper engraving if a less dense wood like pine or larch is used rather than on a more dense wood like oak.

Old School Fabrications then took the engraved wood for finishing and treatment for outdoor use. As you can see, the transformation was incredible, and all the knots and imperfections in the wood added to the beauty of the signs. This picture shows one of them mounted in Edinburgh’s St Andrews Square by the pond, where OSF put a model crocodile to complete the African vibe!

We were lucky enough to get our hands on one of the signs the exhibition was finished. They were no longer required, so ours is in pride of place on the workshop wall.  It’s a great example to show customers when they visit of how they can expect engraved wood to look. And it also shows just how well reclaimed wood can scrub up.