Inside the workshop
How the puzzles are made
Cut, sanded, printed, checked, packed — in one building.
The lines
Puzzle production is four operations: cutting, sanding, decoration and packing. We run laser cutting for small runs and shaped pieces, and die cutting for volume boards. Both are followed by a tumbling and hand-sanding step because a laser-cut edge is square, not comfortable.
Decoration is UV print for artwork and water-based paint for solid colour. Both are cured before packing, and the paint batch is recorded against the test report for that model.
Quality control
Every batch is checked for piece fit, edge quality, print registration, colour match against the approved sample, and small-parts compliance against the age band. A pull test is done on every batch of knobs and pegs.
Test reports for EN71, ASTM F963 and CPSIA are supplied per model with the quotation. We do not print certification marks that we cannot back with a report.