Making Your Own Wooden Puzzles

Are you looking for a fun and engaging DIY project using spare wood at home? Crafting wooden puzzles is a rewarding endeavor that’s both easy and exciting. Whether you’re interested in designing brain-teasing interlocking puzzles or crafting a wooden jigsaw for kids, we’ve got you covered!

Benefits of Making Your Own Wooden Puzzles

The allure of creating your puzzles goes far beyond the joy of solving them; it taps into a deep sense of creativity, craftsmanship, and satisfaction that can be extremely rewarding.

1. It unleashes creativity

Making your own wooden puzzles provides a canvas for your imagination to run wild. You’re not limited to existing designs or predetermined images. You have the freedom to choose shapes, themes, and levels of complexity. Whether it’s crafting intricate interlocking pieces that form an elegant motif or designing a maze that challenges the problem-solving skills of the solver, your creativity sets the limits. Each puzzle you create becomes a unique expression of your artistic vision.

2. It offers a sense of accomplishment

The process of designing and crafting wooden puzzles is both mentally stimulating and physically engaging. From selecting the type of wood to cutting, sanding, and assembling pieces, every step requires precision and attention to detail. As you see your puzzle come to life, piece by piece, there’s a great sense of accomplishment and pride in what you’ve created. It’s a tangible evidence of your skills and dedication.

3. It allows for personalization and meaning

Creating wooden puzzles allows you to infuse your personality and sentiments into your work. Whether you’re making a custom puzzle as a heartfelt gift or crafting a puzzle that reflects your interests and passions, each piece becomes a meaningful symbol. Personalized puzzles can be cherished heirlooms, passed down through generations, carrying with them memories and emotions.

4. It connects you to nature

Working with wood is a deeply grounding experience. It reconnects you with the natural world and highlights the beauty of organic materials. The scent of freshly cut wood, the feel of its grain under your fingertips, and the warmth it brings to your hands create a sensory experience unlike any other. Crafting wooden puzzles also encourages an appreciation for the environment and the sustainable use of natural resources.

5. It can sharpen cognitive skills

Both the creation and solving of wooden puzzles are excellent exercises for your brain. Designing puzzles challenges your problem-solving abilities, spatial awareness, and attention to detail. Solving them enhances your critical thinking, patience, and perseverance. This dual benefit of cognitive stimulation makes the process of puzzle creation a rewarding mental workout.

6. It gives you an opportunity to share and bond with others

When you create wooden puzzles, you’re not just making them for yourself; you’re also creating opportunities for connection with others. Sharing your creations with friends and family, collaborating on solving them, or even teaching others how to craft their puzzles can foster a sense of camaraderie and social engagement.

7. It’s durable

One of the most apparent advantages of a wooden puzzle is its remarkable durability when compared to cardboard puzzles. Thanks to the sturdy wood material, each puzzle piece is robust and less prone to wear and tear. Unlike cardboard pieces that tend to fray and deteriorate at the edges over time, wooden puzzle pieces stay strong. While wooden puzzles may require a slightly higher initial investment, they are built to last for many years. In fact, many people hold onto their wooden puzzles for generations, passing them down as cherished family heirlooms.

Why Play Wooden Puzzles?

a child playing wooden puzzle

Wooden puzzles are enjoyable for all ages, but most especially for children. Older adults can definitely benefit from it, too. There are many advantages to enjoying wooden puzzles.

1. It enhances hand-eye coordination

Playing with wooden puzzles improves hand-eye coordination, as players must manipulate pieces accurately to complete the puzzle.

2. It develops fine motor skills

The intricate nature of wooden puzzles encourages the development of fine motor skills, aiding in precise hand movements and dexterity.

3. It can boost problem-solving skills

Wooden puzzles foster problem-solving abilities by requiring players to analyze and figure out how pieces fit together to complete the picture. Engaging in puzzle-solving enhances critical thinking, as players must strategize and plan their approach to solving the puzzle.

4. It helps improve memory and concentration

Solving puzzles challenges memory and concentration, helping to enhance cognitive abilities over time. This is why wooden puzzles can serve as therapeutic tools for individuals dealing with dementia or Alzheimer’s disease, offering cognitive stimulation and enjoyment.

5. It offers stress relief

Wooden puzzles provide a relaxing and stress-relieving activity, offering a therapeutic escape from the demands of daily life. The touch of each puzzle piece is smooth and substantial, and the scent of the wood as you open the box adds to the sensory experience. The tactile nature of wooden jigsaw pieces enhances your puzzling enjoyment, and the fact that each piece is uniquely shaped showcases the thoughtful craftsmanship behind every puzzle. The satisfying ‘click’ sound as each piece snugly fits into place is music to the ears, accompanied by a sense of accomplishment that never grows old.

6. It’s affordable but durable

With puzzles to fit various budgets, they make fantastic gifts for any occasion, providing hours of entertainment. But if it’s handmade using scrap wood – then it’s free! And thanks to their durable material, wooden puzzles can provide enjoyment for many years, making them a lasting and valuable investment in leisure and learning.

Must-Have Tools and Materials for Making Handmade Wooden Puzzles

a scroll saw in use

Crafting handmade wooden puzzles demands specific tools and materials to guarantee the quality and endurance of your final masterpiece. Key tools in your arsenal should include a scroll saw, wood carving tools, and sanding tools. Here’s a more specific list:

Electrical Tools

  • Scroll saw with various sizes of blades
  • Vacuum cleaner
  • Dremel rotary tool with a long flexible cord neck
  • Tungsten carbide cutter bits (1/8″) and (3/32″), sanding, grinding bits, and bands

If you can have access to a laser cutter, it can help make your wooden puzzle pieces fit together seamlessly. Laser cutting ensures clean cuts, free from dust and impurities, resulting in a snug and satisfying fit when the puzzle pieces come together – a feature often harder to find in cardboard puzzles. Laser cutters are expensive, but if you plan to do more projects using them, check out the different hobbies that make use of a laser cutter.

Quality Plywood Sheets

When it comes to selecting the right wood, opt for top-tier hardwood varieties like maple, cherry, or oak. These woods are robust, resistant to wear and tear, and provide an excellent canvas for intricate designs. You can also use plywood sheets made of Okoume, Baltic birch, Finland birch, poplar, basswood, or any high-quality plywood with no voids or patches.

  • 2/32″ (1/16″)
  • 4/32″ (1/8″)
  • 5/32″
  • 6/32″ (3/16″)
  • 8/32″ (1/4″)

Hand Tools

You will need hand tools for carving, cutting, marking, sanding, and handling wood. Most are available at home improvement and hardware stores.

  • X-acto knife and extra blades
  • Self-stick sandpaper and block
  • Carpenter Squares (in various sizes for stabilizing puzzles)
  • Wood boards (for cutting and removing paper)
  • Work Bench and 6″ bench vise
  • Sets of needle files (small and large sizes)
  • Scratch Awl with a wooden handle
  • Pencil Sharpener
  • Tweezers
  • Caliper (for measuring puzzle thickness and replacement piece thickness)
  • Razor blades (for removing old glue and damaged wood)
  • Clamps
  • Very small flat-end screwdriver (for packing wood into knob holes)
  • Magnifying glass or magnifying goggles (for precision cutting)

Art Supplies

Beyond the tools and materials mentioned, other essential items for crafting handmade wooden puzzles are quality wood glue and coloring materials.


  • Wood glue for wood layers
  • Multi-purpose glue for paper layer
  • Paper Towels
  • Quality hot-pressed (smooth finish) watercolor paper
    • 90-pound weight for replacement pieces and most knob repapering
    • 140-pound weight for thick original paper replacement on knobs
  • Variety of cardboard pieces (for holding assembled puzzles)
  • Architect’s pencil
  • Small brushes for glue and watercolor pencils
  • Plastic wood (natural color)
  • Acetone (for reconstituting dry plastic wood)
  • Watercolor pencils
  • Gum arabic
  • Release paper (for forming molds if dry mounting)
  • Dry mount tissue adhesive (optional)
  • Cans (for holding clean water)
  • Very small glass for glue
  • Sponges (for dampening watercolor pencils and cleaning puzzles)
  • Rubber cement (for holding pieces together when tracing replacement pieces)
  • Rubber cement eraser (for easy removal)

Personal Items

  • Safety goggles
  • Apron
  • Old clothes to wear

Making Unique Puzzle Patterns

Designing patterns for your handmade wooden puzzles is a pivotal step in the creation process. Your patterns should be one-of-a-kind, visually appealing, and engaging for puzzle enthusiasts. Numerous software tools are available to aid in crafting intricate and challenging puzzle designs.

When conceiving puzzle patterns, it’s important to decide the level of challenge you want to present. Some puzzlers love a formidable puzzle that demands time and concentration to solve, while others prefer a more laid-back and leisurely experience.

For beginner DIY woodworkers, it’s best to start with an easy puzzle with bigger pieces. And as you polish your puzzle-crafting skills, you can make more intricate designs.

How to Create a 3D Interlocking Block Puzzle

1. Cut the wooden pieces

  • Begin by taking a hardwood board, such as maple, poplar, or birch, measuring 13 × 2 1⁄4 × 3⁄4 inches (33.0 × 5.7 × 1.9 cm). Mark three 3 3⁄4-inch (9.5 cm) lengths on the board, ensuring about 1⁄4 inch (0.64 cm) between them for clean cuts.
  • Using a miter saw, make straight cuts along the marked lines to obtain three identically sized pieces of wood.
  • Safety first: Don safety glasses before using power tools to protect your eyes from wood debris.

2. Create the grid

  • Draw a 3 x 5 grid on the front surface of each wood piece. Measure every 3⁄4 inch (1.9 cm) along the edges and mark them with a pencil. Draw light, straight lines across the wood, forming a 3 x 5 grid on each piece.

3. Mark and prepare the center squares

  • On each wood piece, mark the 3 or 4 center squares with a pencil. Inside the three central squares that do not touch an edge, draw a large X. For two of the pieces, mark the third square along one of the long edges to create a “C” shape.

4. Cut the “C”-shaped pieces

  • Wearing safety glasses, use a scroll saw with a #7 blade to cut out the “C”-shaped pieces. Follow the outlines of the marked squares, carefully guiding the wood into the blade. Scroll saws have narrow blades for precise, curved cuts.
  • If a scroll saw isn’t available, a hacksaw can be used as an alternative. You may need to cut the squares in multiple pieces if removing them as one unit proves challenging. Be cautious not to apply excessive force to avoid damaging the saw or risking injury.

5. Drill for the final piece

  • Using a drill bit slightly wider in diameter than the scroll saw blade, drill through the middle square on the remaining wood piece. Ensure the drill is placed adjacent to the square’s outline and apply gentle pressure to guide the bit through the wood.

6. Cut Out the “O”-shaped piece

  • Insert the scroll saw blade through the hole drilled in the wood piece. Turn on the saw and carefully guide the wood through the blade, following the outlines of the three central squares to remove them. Keep your fingers away from the saw blade during this process for safety.

7. Smoothen the edges

  • Use sandpaper of any grit to smooth the cut edges of the wooden pieces. Fold the sandpaper and gently rub the sides of the cut wood pieces. Test their movement by sliding one piece through the middle hole of another to ensure a smooth fit.
  • Optionally, you can use sandpaper to remove the grid lines you drew instead of using an eraser.

Creating a 3D interlocking block puzzle involves cutting and shaping wooden pieces with precision, prioritizing safety throughout the process.

Making Your Own Wooden Jigsaw Puzzle

wooden jigsaw puzzle shaped like a lightbulb

1. Affix the image

  • Begin by taking a piece of plywood measuring 8 inches by 10 inches (20 cm by 25 cm). Place your chosen photo upside down next to the plywood of the same dimensions. Holding a can of spray adhesive a few inches above both the photo and the plywood, apply an even layer to the back of the photo and the plywood’s surface. After approximately 30 seconds, carefully press the picture onto the plywood.
  • Feel free to use any photograph you like or print a picture onto a sheet of paper for your puzzle. To protect the surface underneath from the spray adhesive, place your photo and plywood on a scrap piece of cardboard.

2. Outline puzzle shapes

  • Lightly sketch the shapes of the puzzle pieces onto the photo using a pencil. This will serve as your guide for making cuts. Create random shapes for each piece, ensuring that at least one knob-like projection extends from a side of each piece to allow for interlocking. Once you’re satisfied with the outlines, you can proceed.
  • If you prefer not to draw your own puzzle pieces, you can print an 8-inch by 10-inch puzzle template and tape it over the photo.

3. Cut with a scroll saw

  • Prioritize safety by wearing safety glasses before you start. Activate your scroll saw and gently guide the plywood through the blade, following the outlines of the puzzle pieces. Adjust the wood’s orientation to accommodate any curves as you cut out each individual piece.
  • Avoid rushing the cutting process to prevent mistakes or damage to the saw.

4. Sand for smooth edges

  • To refine your puzzle, use sandpaper of any grit. Delicately rub the cut sides of the pieces to eliminate any fuzzy or rough edges left from the saw. While sanding, test the pieces to ensure they fit together smoothly without resistance.
  • Be cautious not to over-sand the puzzle pieces, as this could hinder their interlocking or create a loose fit.

5. Protect with spray lacquer

  • If you wish to preserve and protect your puzzle, consider applying a clear coat of spray lacquer as a finish. Shake the can, and while working in a well-ventilated area or outdoors to avoid fumes, hold it a few inches above the puzzle. Spray a thin coat of lacquer vertically over the fronts of the puzzle pieces and allow it to dry. Apply a second thin coat, this time spraying horizontally.

Making Your Own Wooden Tray Puzzle

1. Create the puzzle outline

  • Start with an 8-inch by 10-inch by 1/8-inch (20.32 cm by 25.40 cm by 0.32 cm) piece of plywood for your puzzle base. You can either freehand your design with a pencil directly onto the plywood or opt for an easier approach by printing an outline that fits the plywood dimensions and using spray adhesive to attach it.
  • Ensure the outline does not extend beyond the plywood’s edges.

2. Drill a starting hole

  • Use a drill bit slightly wider than the saw blade you intend to use. Position the drill tip on the inside of your outline, as close to the design as possible. This hole provides a starting point for cutting. Put on safety glasses and drill straight through the plywood.

3. Cut the shape

  • Employ a scroll saw to cut along the inside of your outline. Prioritize safety by wearing safety glasses. Start the saw and carefully guide the wood through the blade, following the inner edge of your outline to cut out the shape.

4. Smooth the edges

  • Opt for 240-grit sandpaper for the smoothest finish. Gently sand the edges of the cutout shape to remove any rough or fuzzy areas. Similarly, smooth the cut edges on the piece of plywood. Test the fit by placing the cutout shape into the hole in the plywood, sanding more if necessary to ensure a proper fit.

5. Glue to MDF

  • Flip the cutout plywood piece and apply a thin layer of wood glue over its surface. Place the plywood atop an 8-inch by 10-inch by 1/8-inch (20.32 cm by 25.40 cm by 0.32 cm) piece of MDF, ensuring the edges align. Utilize C-clamps to hold the plywood and MDF together until they dry, typically taking about a day.
  • The MDF serves as the tray’s bottom, allowing the puzzle pieces to interlock within the cutout without falling out.

6. Create puzzle pieces

  • While the plywood and MDF are drying, lightly sketch the desired puzzle piece outlines onto your cutout design using a pencil. You can draw the pieces to your preferred size, making sure to include a knob-like extension from one side to enable interlocking. With safety glasses on, operate a scroll saw to cut out the individual puzzle pieces, following your outlines.

7. Sand puzzle piece edges

  • Use the 240-grit sandpaper to smooth the edges of the puzzle pieces. Test-fit the pieces into the tray as you sand to ensure they interlock seamlessly.
  • If the pieces prove challenging to assemble, a little extra sanding may be necessary.

8. Add creative touches

  • If desired, enhance your puzzle by painting the pieces with acrylic paint or spray paint. Apply a thin coat of paint, allowing it to dry completely before adding a second coat. Once your painting is complete, your puzzle is ready for enjoyment!
  • To make it easier for kids to fit the pieces, consider painting the bottom of the tray in the same colors as the puzzle pieces.


In a world filled with digital distractions, making your own wooden puzzles offers a refreshing break from screens and a chance to reconnect with the tangible world. The allure lies not only in the final product but also in the journey of creation itself. It’s a satisfying blend of creativity, craftsmanship, and intellectual challenge that can bring joy and a sense of achievement by doing something with your hands. So, if you haven’t already, consider picking up the tools and exploring the enchanting world of crafting wooden puzzles. As you try to make your own wooden crafts, don’t forget to follow these safety tips for woodworking projects.