I have been cutting jigsaw puzzles since 1989. I use a fret / scroll saw with very fine blades.
Each puzzle is cut freehand one piece at a time using a premier quality 6mm birch plywood, as a result each piece is unique.
After sanding the ply to a smooth finish the picture is permanently bonded on to it. When the puzzle is cut, each piece is inspected and counted before being boxed.
Putting together a wooden jigsaw puzzle is an experience not to be missed for anyone who enjoys a challenge. Many people have said cardboard puzzles just don't do it for them anymore.
For children I use the same 6mm premier plywood to make into tray / inlay puzzles. The pieces are given two coats of acrylic toy safe paints, varnished, then plastic wrapped to send out.
Stand up puzzles are made from 18mm thick plywood or 18mm hardwood, depending on what is available at the time.
I also cut names out these are made the same way as tray puzzles with capital letters 75mm high lower case letters 60mm high and painted with acrylic. If names are too long for my saw a smaller font will be used.
Tom Middleton
Custom Jigsaw Puzzle Maker