How to Laser Cut a Jigsaw Puzzle with a Laser Cutter [with Tutorial Video]

by Winnie Li Posted in February 13, 2023

Using a laser cutter, you can make unique, appealing, and incredible wooden jigsaw puzzles that the kids would love to have and play with. If your children are tired of playing with old puzzles, it is time to make something new and exceptional.

Even if you are a beginner or it is your first project, you can try this one. You can make it for your loved ones, and it is pretty simple. Other than that, you can also sell such items and make an extra profit.

Here is a complete guide to making a laser cut wood puzzle quickly. Follow the steps, and you will end up making a flawless laser cut jigsaw puzzle.

Things You Need to Laser Cut a Puzzle

Laser Cutter and Software

The most important thing is the laser puzzle cutter. You can use xTool D1 Pro, M1, or any other machine that can cut and engrave wood easily. Install the software and make sure it is updated.

xTool D1 Pro Diode Laser Engraver

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xTool M1 Laser Engraver

xTool M1: The Ultimate Gift-making Laser & Blade Cutting Machine

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£799.00

£1,149.00

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Plywood

Plywood is the only material you need to make a laser cutting wood puzzle. You can choose a suitable thickness of the plywood and its type, but 3mm basswood plywood is an excellent option to go with. Keep in mind that you need two pieces of plywood of the same size. One will be the cut jigsaw puzzle, and the other will be used for its base.

Glue Gun

A glue gun is a must to stick the outline of the jigsaw puzzle and the base. You can also use wood glue if you don’t have a glue gun.

Color Paint

If you want to make the puzzle eye-catching, it is a must to paint it. You can use any paint you like, such as spray paint, acrylic paint, etc. But it is better to use paint pens if you want to stay away from the mess.

Step-by-Step Guide to Make a Jigsaw Puzzle with xTool M1

Once you have all the materials and things you need, it is time to use the machine. Follow the steps carefully to get an error-free laser cut wood puzzle in one go. We are making a cute cat jigsaw puzzle that cat lovers and children would love to have.

Step 1: First, you need to set up the machine. Place the triangular prisms on the base plate of M1. It will improve the ventilation process. After that, place the 3mm basswood plywood carefully on the prisms.

Step 2: Connect the exhaust pipe or smoke purifier to the machine. Then, connect the machine to the computer using the USB cable. Turn on the machine.

Step 3: Open XCS on your computer/laptop. Make sure the machine is connected. Import the laser cut puzzle template to the software. You can import the outline or the vector file of the puzzle in the first place. Adjust the placement of the outline over the wood by looking at the live preview.

Step 4: Select the 3mm basswood plywood in the material and set the height raised to Triangular Prism. Click on Cut. There is no need to select settings manually because M1 sets the optimal settings when you select the material.

Step 5: Import the engraving file, which is for the cats' facial expression. It is an image or raster graphics. Place it over the outline. All images are set for engraving by default, and as you have selected the material, there is no need to adjust the settings. Just make sure to set the sharpness to the max.

Step 6: Before engraving, you can adjust the size of the whole puzzle. Select everything and adjust the size. Click the Process button. Click Framing if you need to check the outlines, but there is no need for that as you have the live preview. Finally, click the Start button and press the button on M1.

Step 7: The machine will start its job. Once everything is ready, take out the puzzle from the engraving area. It is time to paint the puzzle. You can use any kind of wood color to make your puzzle more appealing. Apply hot glue at the sides of the plane basswood sheet and place the puzzle outline over it. Let the glue dry.