HOBON, a leading OEM and ODM printing enterprise in China, has been manufacturing high-quality jigsaw puzzles for nearly three decades. The production process at HOBON combines precision craftsmanship with advanced technology, ensuring every puzzle piece fits perfectly and delivers a premium tactile and visual experience.
Here’s an overview of how jigsaw puzzles are made at HOBON:
1. Material Selection
The process begins with carefully selected raw materials. HOBON offers a range of core boards including:
- Blue core board
- Orange color core board
- White core board
- Black core board
- Greyboard
- Brown core board
These materials are chosen based on the project’s requirements for durability, color fidelity, and budget.
2. Image Printing
Using Heidelberg four-color printing presses, the chosen artwork is printed on high-quality paper, typically 157gsm C2S art paper. Depending on the desired visual and tactile effect, various surface treatments are applied:
- Matte or glossy film
- Cold foil
- Holographic foil
- Soft touch lamination
- Glow-in-the-dark finishes
- Glitter or silk screen effects
These enhancements not only improve the product’s visual appeal but also its market competitiveness.
3. Mounting
Once printed, the artwork is mounted onto the core board using high-precision lamination. This process ensures that the image adheres seamlessly to the puzzle board without bubbling or wrinkling, which is crucial for clean, crisp puzzle pieces.
4. Die-Cutting
HOBON uses automatic die-cutting machines to press the mounted board into puzzle pieces. The die-cutting lines and piece counts are fully customizable, with standard adult formats including:
- 500 pieces (20×20 inch or 18×24 inch)
- 1000 pieces (various sizes, including round options)
For children’s puzzles, counts range from 12 to 56 pieces, including special floor puzzles.
5. Packaging
Puzzles are packed in custom-designed boxes, with numerous packaging options available:
- Lid and bottom box
- Slip case box
- Scene box
- Book-type gift box
- Irregular shape boxes
- Paper tube and PET tube
- PE pouch bags, biodegradable bags, kraft paper bags, canvas bags
HOBON provides packaging that aligns with your brand identity and complies with environmental regulations, particularly in Europe and North America.
6. Value-Added Features
To elevate puzzle functionality and consumer engagement, HOBON incorporates features such as:
- Sound-producing components
- Wind-up track puzzles
- Flap and search-and-find puzzles
- Coloring book & puzzle sets
These innovative elements add play value and enhance retail appeal.
7. Quality Control
Throughout the process, HOBON implements a strict quality control system, monitoring every stage from raw material procurement to final shipment. Each batch undergoes rigorous checks to ensure dimensional accuracy, print consistency, and secure packaging.
HOBON’s modern 12,000 sqm facility, equipped with a full suite of automatic equipment and staffed by a skilled team, produces puzzles for global markets including the U.S., U.K., Italy, France, and Japan. The company’s commitment to innovation, customization, and quality has made it a trusted partner for international puzzle brands.
About Hobon Printing
Established in 1995, the predecessor of Hobon is Weidong Arts and Crafts Factory, which mainly produces decal paper for ceramics, wood products and so on. With the development of The Times, Hobon Printing Brush continues to introduce new equipment and technology, products also cover board games, puzzles, cards, paper packaging, etc., to become a comprehensive printing enterprise.For inquiries, collaborations, or customer support, feel free to contact the team at se*****@***********ng.com
