Normally, from the time I get the image to when it is a finished product will take from 10 days to two weeks, depending on the preparation time for the images, intricacies of cutting, the total number of pieces, and what other puzzles may be in other states of development.

It all starts with a conversation with the customer to determine what you want. This may be short or long, in person or by mail or e-mail. I make sure to take the time needed to figure out exactly what will be the perfect puzzle to make for each customer’s needs and wants.

Then I begin the hands-on processes, starting with the picture, which is either something that I’ve selected or was supplied by you, the customer. If it is non-digital artwork to be returned, I scan it into the computer to work from a digital copy. Otherwise, I will be working from a digital file either sent to me by e-mail or provided in some other way.

Once the image is digitized, I print it on either photo-grade matte or glossy paper (the choice depends on the details of the picture and the desired finish requested by the customer.) I currently have several print options available to me, all of which are six-color Epson printers. Currently two use dye-based ink, one has pigment based inks. (Eventually I will convert all the printers to use pigment inks as they are more fade and water resistant.) One is a typical 8.5" wide model which includes my scanner, the second has a 13" wide capacity that can easily produce 13x19 wide format HD prints, and the third is a grand 24" wide (but it has some quality issues…which will eventually be resolved.) Plus, I have a source that could print things up to 44" wide, but that would require very creative cutting methods…

Once the prints dry, they are mounted on ¼" prepared plywood which is cut to the rough size of the print. I use a dry-mount press with adhesive material cut to size for each print.

Once mounted, it gets a coat of fixative to prevent the final coating from causing any ink runs. It is further protected with two coats of sprayed acrylic. This gives a beautiful finish, protects the picture during cutting, and preserves it for years of put-together-and-take-apart action. Each layer takes is given a dust-free overnight drying period. (This is where having one puzzle in the cutting stage may delay the preparation of the next puzzles in the pipeline.)

After the finishes have dried, each blank is inspected for flaws (image/coating issues will cause me to toss a blank at this point and start over again…) Assuming all is acceptable, it is cut to finished edges. This may be on a table saw or on the jigsaw, depending on the edge style: straight or wavy.

Then comes the fun.

All the interior cutting is freehand on the jigsaw. I only use patterns for some of the special pieces when I need to get a particular shape JUST right. (Eventually you will be able to look on the samples page for the running man piece and the biking man piece. The running man was cut totally freehand, no pattern. The biking man was done from a pattern carefully held by one hand while cutting with the other, so that I could get perfectly round, matched wheels.)

As I cut, I place the pieces aside, re-assembling the puzzle as I go. This ensures I don’t lose a piece into the dark recesses of the workshop and have to go hunt it down later. After the cutting is finished, the puzzle is flipped over and the back and outside edges get a final sanding. After dusting, the back receives two coats of wipe-on varnish to seal it and give a finish with a pleasent, natural look and feel. (Of course, some folks might take advantage of this while assembling, and flip over the pieces to find out which way the grain of the wood is running.)

If I remember, I then take pictures of each finished puzzle.

After the puzzle is disassembled, the puzzle pieces are counted and inspected for flaws. The major flaw I find at this step is a spot where the paper has separated into layers from friction while cutting. These can normally be glued without affecting the appearance of the puzzle. (Although, if the flaw visually affects the final appearance, I toss the whole thing and start over to get it right.) The count is verified and the signature piece gets it’s namesake: my signature. Also included on that piece are the date completed, the puzzle serial number, and the total number of pieces. (This gets tricky on two-sided puzzles, as all this has to be written around the sides of the piece, since there isn’t any back!!)

If I didn’t remember earlier, I then have to put it back together to take pictures of the finished product. (I’ve done this enough times that I haven’t forgotten lately… but I will forget again, I'm sure…)

All my boxes are the same width and length, but come in several depths to accommodate different puzzle sizes. The common size allows easy storage together on bookshelves. (hint hint… Buy more than one!! Call and ask me about frequent-buyer discounts!!) Larger puzzles will be packed in multiple boxes so that pieces won’t be damaged with too many crowded in on top of each other.

Finally, if I won’t be hand-delivering it, the boxed puzzle is packed in a USPS priority box and shipped to you to provide happiness… and a little enjoyable frustration, I hope!.

Honestly, the most patience-trying part of this whole process isn’t the cutting of the puzzle. What does take a lot of patience is the preparation needed to get to the point of being ready to cut. Too many things can go wrong or be rushed!! The picture is too red or too blue or too light or too dark, or not centered, or any number of other things. Or the ink runs or the printer spits schmutz on it. Or the acrylic doesn’t behave, or it gets burned or under-cooked when mounting it… All THESE things frustrate me more than the cutting.

The cutting is an enjoyable challenge… different with each new order. It is a contest between me and the people that will be assembling it later! As I cut, I look for ways to make it interesting… ways to make boring areas fun… the exact best spot to cut in my signature piece and the other specials. These things make the cutting fun, a reward for getting through all the prep work!!

If you aren’t convinced that having a one-of-a-kind, numbered, signed piece of art made from your own picture isn’t worth it in it’s own right; please go back to the section above, which explains much of what contributes to the cost. There are many hours of time spent in preparation, cutting, finishing, and counting. (I don’t charge for the time to re-assemble it if I forgot to take pictures…) Add to the labor the cost of ink, paper, wood, finishes, saw blades, boxes, utilities, packing, shipping, and… voila! An expensive piece of merchandise!! Then you also add that ethereal thing called "overhead": advertising, liability insurance, accountant’s fees, time and money spent filing paperwork to be allowed to be a business, and all those other mundane things that are a part of providing these pieces of art in a box… it quickly adds up. I wish the price could be less, but I’m already only "paying" myself minimum wage, and doing some stuff for free! (Remember: you can email me if you want to ask about multi-purchase discounts…)

Consider this comparison: an 8x10 "standard" puzzle of 200 pieces will be around $300 plus shipping. This is less than I had to spend to get a new computer I needed to run the bookkeeping software to track the business. AND… the puzzle will continue to function and provide enjoyment without ever needing an upgrade, using any batteries, or generating any pollution! (At least, no pollution once all the finishes are completely dry…) Not only that, it can be a multi-user event, contributing to family togetherness! All in all, I think they are a pretty good deal for the cost, but I might be a little biased in my opinion on the matter…

My name is Paul Casacci. I've been woodworking since high school and have made practical things (like shelves and book-ends and lamps) and unusual things (like a harsichord!)

I grew up in South Jersey and majored in both mathematics and music at Glassboro State Collage. My woodworking was a part of much of my life even there. I was a bassoon major in the music department - and have taken apart, refurbished, and reassembled a contra-bassoon. I'm a baritone and have sung the part of the Judge in Gilbert and Sullivans' Trial by Jury - while also participating in the construction and painting of the sets.

We lived in a house in VT whose only source of heat was a woodstove while it read -37F degrees on the thermometer - in which I installed, by hand, replacements for rotten beams, and completed many other renovations before we left to move SOUTH to where we live here in Wales, Maine.

As of now, cutting puzzles isn't my day job. By day, I'm a computer systems analyst (not my official title, but it is what I do…) and have been since 1978. I got started making puzzles when I refurbished the jigsaw attachment, cut a couple puzzles, and found that I really enjoy the challenge and satisfaction of making them. And, people that have had a chance to work on re-assembling my puzzles enjoy them. (At least, that's what they tell me…) So, I considered it for a while, and eventually decided to take it to the next level and try it as a business. So, here I am…

Making puzzles lets me use manual talents, which I enjoy, to acheive a goal. It also allows me to use my computer skills, not as a programmer, but as a tool to support the business and to provide the images which are an integral part of the puzzles and this website!

I think the comments that mean the most to me are those made when a puzzle is complete, and I am asked when the next one will be ready…

If not, please click below to send me your questions by e-mail and I’ll try to come up with some sort of reasonable (or unreasonable) answer. Maybe you’ll even see your question here someday!!