I cut my jigsaw puzzles by hand from 3mm (1/8″ nominal) medium density fiberboard (MDF) panels.
This material is typically used as a wall covering in many homes. MDF is an engineered wood product made from natural wood fibers. Because MDF is made from waste wood it is eco-friendly.
The pictures are bonded to the wood panel and then each puzzle piece is hand cut using an electric saw that is fitted with a very fine 0.008″ blade, NOT a laser or water jet cutter controlled by a computer. The puzzles are then assembled to insure that all pieces are present and of the highest quality. A final coat of matte finish lacquer is applied and the puzzles are disassembled and packaged.