How to make a personalized jigsaw puzzle

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introHow to make a personalized jigsaw puzzle

This Instructable shows you how to make a personalized laser cut jigsaw puzzle using Ponoko. If you've never worked with a laser-cutter or have only used a vector art package once or twice before, then this guide is for you.

This Instructable follows the same structure as my previous Instructables on making a laser-cut lamp and jewelry but it a little more experience (or persistence ) is needed for the Inkscape stages. As long as you've got a computer that can run a vector software package you'll be able to achieve some very cool results.

If you prefer to skip the Instructable and just get making, feel free to download the .eps files I've already created.

Let me know how you get on!

How to make a personalized jigsaw puzzle

step 1Stuff you'll need

You'll only need a few things for this Instructable: A steady hand [http://www.inkscape.org/ Inkscape] [http://www.ponoko.com/makeandsell/downloads?utm_source=instruct…

step 2Download and open Inkscape

If you haven't already got Inkscape installed, head on over to [http://www.inkscape.org/ Inkscape.org] and download the latest version of Inkscape for your computer. Inksca…

step 3Download and open the P3 template

You're now ready to download and open the Ponoko [http://www.ponoko.com/makeandsell/downloads?utm_source=instructables&utm_campaign=instructables-02Apr08&utm_medium=webpage…

step 4Construct a grid

I set up some guide lines as a grid to help space me space my cut lines. You can create guide lines by clicking in the ruler area on the left and top of the window, hold…

step 5Draw the puzzle pieces cut line

Firstly I created a bounding box so I know where the pieces will be contained. I made this 340mm x 340mm so that it would fit nicely on a P3 template. Using the Pen Tool…

step 6Copy, paste and rotate

To keep it simple I simply copied and pasted the jigsaw line 14 times and arranged them on the grid. To mix it up, so all the pieces were not the same, I used the flip a…

step 7Outline and border for the pieces

I created a rectangle around the outside of the puzzle pieces which will become a frame for the puzzle later. I made it 370mm x 370mm so that there is a 15mm border on all …

step 8Find/create an image

James thought that it would be a good idea to use a map for an image on the puzzle. I went to Google maps, located Wellington, NZ (home of Flight of the Concords) and panne…

step 9Convert PDF to JPEG

Inkscape can't open PDF files so you need to convert it to a jpeg or a bitmap. I used Photoshop to do this but you could use any graphics program that will open or import a…

step 10Open map image in Inkscape and start tracing

Under the File menu you will find Import. Select this and open the map image you have converted to a JPEG. Position it off the side of the template for now. Using th…

step 11Fill the water

Now that you have traced the water, open the Fill and Stroke box from under the object menu. With the area of the water selected fill with a grey (R:128 G:128 B:128 A:255) …

step 12Tracing main road

The map has 3 different types of road indicated with different colors. I am going to treat all these with different types of engraving so that there is variation in the puz…

step 13Tracing more roads

The yellow roads are traced next. I started at the top right point and traced around the entire outside shape. I then went and traced the internal voids and I show how to j…

step 14Excluding filled areas

As in the first image, select one of the internal shapes by clicking on the outline. While holding down the shift button, select the outside shape (the large shape created …

step 15Tracing the smallest roads

Using the pen tool, trace the lines of the smallest roads. I only want to have a vector type engraving on these roads to add another level of hierarchy so I only needed to …

step 16Changing colors and line weights

With the light grey roads selected, open the Fill and Stroke box again. I wanted to put a light vector around the perimeter to add some crispness to the engraving. Set t…

step 17More line colors and weights

Select all the smallest roads. Change the line color to green (R:0 G:255 B:0 A:255) and the line weight to 0.003mm. With all the lines still selected, go to the Object …

step 18Resizing map

Select all the map objects and 'Group' them together.Resize the map to be the same as the jigsaw pieces we drew earlier. In this case the size needs to be 340mm x 340mm.

step 19Changing line weights and colors of the jigsaw pieces.

We need to tell the laser cutter which lines to cut. With all the lines needing to be cut selected assigned the following values Color - Blue (R:0 G:0 B:255 A:255) Lin…

step 20Combining everything

Move the map image onto the template in line with the jigsaw pieces. Image 2 shows how to raise the blue cut lines to be on top of the filled areas of the map. The order…

step 21Save as an eps file

Currently, Ponoko only accepts .eps files. Choose "Save As..." from the "File" menu. A dialog box appears (see image below). Change the name to "jigsaw". Now choose "Enc…

step 22Uploading .eps files to Ponoko

Your .eps files are ready to now upload to Ponoko! 1. If you've already got a MyPonoko account - then [https://www.ponoko.com/account/login?utm_source=instructables&utm_…

step 23Choose a material

It's time to choose a material. While still in MyPonoko, click on the "Show me the material catalog first" button or [http://www.ponoko.com/makeandsell/materials?utm_sou…

step 24Adding materials to your .eps files

Once you've made a choice, select your material for each .eps file. Go back to your MyPonoko account and click the "Yes" button under the 'Would you like to add material…

step 25Make your puzzle

The final step in MyPonoko is to make your decorations. Click the "Make it" button to start making. The first screen confirms the details of your order as well as sho…

step 26Laser cutting...

So what happens between the time you make your order to when your parcel leaves PonokoHQ? A few people asked how the laser-cutter works its magic, see [http://www.instructa…

step 27Peel off the backing

Once you receive your parts, peel off the top sheet which holds all the pieces together and the protective backing on the bottom side of all the parts.

step 28Assemble the base board

Take the rectangle with the hole cut from the center and apply double sided table to the back of it. You could also use glue but you would have to leave it for some time to…

14 comments
Jul 19, 2008. 7:22 PMapisays:
(removed by community request)
Jul 22, 2008. 3:14 PMdanemerysays:
You can use Ponoko from anywhere in the world.
Jun 21, 2008. 2:06 AMhelifinosays:
If you're going to do a map, there's an easier way than tracing. Find your area in openstreetmap and, in the export tab, choose "OpenStreetMap XML Data". Then use Osmarender (xsl transform) or or/p (perl transform) to generate an svg (it even makes a nice border). Then open the resulting SVG directly in inkscape and change the colors.
Jun 21, 2008. 3:20 PMdanemerysays:
Wow. Thanks for the tip. I'm sure that will make generating the map much easier.
Jun 19, 2008. 12:17 PMzjharvasays:
Mac Users: In iphoto, open the pdf of the map and click file: export. Then choose jpeg. I found this out after trying for 10 minutes to import a pdf in to inkscape. Should of read step 9!
Apr 2, 2008. 6:30 PMbadweaselsays:
Can I ask what the total cost was (not including shipping)?
Apr 3, 2008. 3:24 AMsolo.cardsays:
You can just about make it out on Step 75 -- $72.
Apr 2, 2008. 12:15 PMsolo.cardsays:
Nice instructable,

I was going to use Ponoko for a small project myself, but the shipping charges are just too high to make it worthwhile.

One day, maybe!
Apr 2, 2008. 2:27 PMjdlewissays:
Hey solo.card - I work at Ponoko. I was wondering if you've checked out our shipping costs lately. We were able to lower our shipping costs, especially for US-based users (assuming that's where you are...) thanks to our new manufacturing node in San Fran.
Apr 2, 2008. 3:31 PMsolo.cardsays:
Hi, yeah I had a look on the site today for the project I had in mind.

Unfortunately, I am based in the UK, so I was looking at $60 (ish) charges, which was about the same (possibly a little more) than the actual cost of the materials, etc.

But If/When you get more locations in Europe, I shall be on board!

Apr 2, 2008. 4:54 AMgmjhowesays:
Very good, and clear instructions, great idea using inkscape, making this vailble for every one! +1!
Apr 2, 2008. 4:55 AMgmjhowesays:
well i would rate it, if i could!
Apr 2, 2008. 3:37 AMBrennn10says:
WOW. Awesome instructions which able anyone to do it. Very nice work!
Apr 1, 2008. 11:11 PMWeissensteinburgsays:
That's awesome! Very nice instructions, and a great idea, too.

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