PD26 part 3: DIY
- Feb 13
- 4 min read
So while we wait on tariffs and checks in the mail to decide if we should order puzzles with boxes or without, I've got a couple projects to work on. One is redesigning the labels to apply on a craft colored box as we figure out the needed dimensions. We want them to still coordinate with the branding of the big puzzles and stickers. Then the next step would be creating mockups.
The other project, I'm checking out the feasibility of a Frame Combo: 4 poly-bagged puzzles with 4 frames. How cool would it be to not just share the experience of assembling the puzzles together but then you would have 4 frames handy to pop the finished puzzles into. Each party guest could receive their framed art or the host could have a little collection to hang as a group. We need to source frames and calculate box measurements with frames and bags. I can design packaging and setup mockups for both options.
**Wait since these are within the size of our equipment, could I make these puzzles on the Cricut? New rabbit hole... I've started looking into how to make puzzles on Cricut and it does look possible. You print your image on sticker paper, adhere it to cardboard or chipboard, then run it through the Cricut. I found a cutting template -though I'm still hunting for one with more pieces. I just ordered some heavy chipboard sheets which should arrive by the end of the week. Then I'll test it out and see how the quality feels -if this works it could be a game changer. We could avoid inventory by printing on-demand and our costs aka pricing could be much lower. The key will be quality. I know they won't be as good as say a Ravensburger puzzle but if better than Dollar Store puzzles this could work. We can balance out quality with a novelty experience and/or price. Frames are looking like a more enticing add-in.
Only issue I can think of right now is the template I found is smaller than 8x10 which then wouldn't fit our initial frame size. It's also less pieces than I want to do. The square template could be easier to resize and there are 8x8 frames that you can buy in bulk. I'm also going to hunt for better template options... OK, I went ahead a purchased a digital template pack for puzzle cut lines and have resized a few to 8x8. I'm going to run some tests initially on just card stock to see how the piece count to size feels.
I tested 4 square puzzle templates: 324pc, 256pc, 225pc and 100pc. They all printed and cut cleanly, look great on first run. I tested on the cardstock and then on magnet paper. The first one's pieces (324) are adorably small -definitely look mini. Pain to weed off the cutting mat though. Not much noticeable difference between the 256pc and 225pc, so will nix the 256. 100pc looks so much bigger than others, these are more like standard puzzle piece size. I wish I had one in between 100-225 but these are still doable. I think we could offer multiple counts as difficulty levels. 100pc is the speed pack, I assembled that puzzle pretty quick. Could be good for party distractions, time limits, or kids. The 256pc took more patience and sorting. Gave more of a real jigsaw experience at a smaller scale but still can do same day. The 324pc, I may revisit bc its cute but I'm not ready to tackle assembling it yet. I'll focus on the other two first.
The ones I assembled I had printed on magnet paper. The first I did 100pc and laminated it before cutting. The laminate sucks to apply, its very unforgiving if you don't align perfectly and it bubbles easily. However in comparison to the next puzzle 225pc I printed without the laminate, I liked the laminate. It firmed the pieces more and they snapped together better. Also without it the edges curl/fray a bit. So the 3rd puzzle 225pc, I laminated and again nicer fit but the spots with bubbles are peeling. I either need to get more skilled at applying laminate or see if I can find a machine. I'm nervous how I'm going to do applying the sticker paper to the chipboard without bubbles. I did order a lamination machine and it is a game changer. It's not foul proof, half my tests did still get a bubble but the bubble was a negotiable wrinkle flaw vs actual bubbles (plural) that I was getting manually.
All the puzzles fit in the 4x6" resealable bags I ordered. I whipped together some card insert mockups on cardstock and I feel they look great next to the original puzzle boxes. Feeling really excited about these.
I just need to finish determining if the chipboard will work. If it doesn't then we'll focus on magnets only.
Oh boy, product pivot. Chipboard just arrived and the size in the photo did not match actual product description. My bad for not proof reading before purchasing (will I ever learn?). So resizing designs to 8.5 x 5.5 but even if I can figure out a workaround for how to resize all the addon materials to the Cricut setup, I'm having second thoughts if it's safe to run through the machine (thickness) without risking breaking anything. I think it's be best to repurpose the chipboard to other projects. Luckily the magnet paper does work!
