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When asked for advice on how to create a unique jigsaw puzzle style incentive poster, we put our thinking caps on and came up with the following clever idea. It involved using digital print output, combined with lamination and our digital finishing expertise. What our client wanted to achieve was a re-usable jigsaw poster which had the mouth section missing from the display. There was to be a lucky-dip bucket filled with a few hundred odd shaped pieces, one of which was the right shape to fit into the mouth aperture. As always on these one-off ideas, tooling was the bug bear that so often kills a job dead.
However, our ability to use drag knife plotting systems and Co2 laser devices gives us a powerful advantage over our competitors! Using the client's supplied artwork file, we ran a full size A1 poster onto a heavy weight coated paper. This was then overlaminated with a matt finish polypropylene film to protect and enhance the design.
 Given that the client wanted to create a larger than life size jigsaw puzzle, which looked and felt like the real McCoy, we had to make use of a 2250 micron thick grey dutch board. This gave the poster some real substance, and to a part, looked just like a real jigsaw.
 We then laminated the digital print directly onto the grey board, and trimmed it up square. The clever bit came next! Using a digital plot file that resembled a jigsaw's individual piece profile, we carefully plotted the intricate mouth shape out using one of our Zund™ flat bed plotters.
This computerised drag knife system allows us to cut complex shapes without any tooling, making it perfect for one--offs and specials. Equally, we had to use the self-same overall process for creating the 400 or so missing mouth jigsaw shaped parts. These were to be the pieces that were mixed up in the lucky dip bag, which the participants dipped into to try and find the missing piece that would drop directly into the open mouth.
It was an absolute success as far as everybody was concerned, and the whole idea worked brilliantly, so much so that the job has been repeated twice over since!
For ideas like the above Mona Lisa poster and similar, why not contact us today for help on that next troublesome enquiry?
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