Laser-Cut Puzzle – A4 Size (8×6 Pieces)

📐 Specifications:

Size: A4 (210 mm × 297 mm)

Pieces: 48 (8 columns × 6 rows)

Material: 3 mm birch plywood (or similar flat wood)

Assembly: Interlocking puzzle, no glue required

Finish: Optional engraving or printed overlay (photo, design, text)

🛠️ Materials & Tools:

xTool S1 (20W) laser cutter

3 mm birch plywood sheet (A4)

Air Assist ON (Auto mode)

Masking tape or paper (for cleaner engrave or photo transfer)

Optional: Clear varnish or oil for finish

Optional: Engraving spray or Mod Podge for image transfer

🧰 Laser Settings:

Cutting puzzle outline:

Power: 100%

Speed: 8–10 mm/s

Passes: 1

Air Assist: ON

Engraving (if adding image or texture):

Power: 30–40%

Speed: 100–120 mm/s

DPI: 254 or 318 (depending on detail)

🧾 Step-by-Step Instructions:

Design the puzzle layout

Use software like LightBurn, Illustrator, Inkscape, or XCS.

Set the artboard to A4 size (210 × 297 mm).

Create a grid of 8×6 puzzle pieces using a puzzle generator or vector path tool.

If you want curved/organic piece shapes, use puzzle plugins (e.g., for Inkscape).

Add optional design or engraving

You can engrave an image, logo, pattern, or even a photo.

Make sure it aligns perfectly with the puzzle grid.

Mirror the design if you're engraving from the back.

Prepare the material

Apply masking paper/tape to reduce burn marks and keep the surface clean.

Place the A4 plywood sheet into the xTool S1 bed and align corners.

Laser engraving (optional)

If you're engraving a design or photo, run that job first.

Check focus and DPI settings.

Laser cutting

Set the path for the puzzle lines and run the cut with air assist.

Watch for piece movement — reduce speed slightly if needed.

Remove masking

Peel off tape carefully after cutting.

Optionally sand edges lightly for smoother touch.

Finish (optional)

You can apply clear spray varnish or natural oil.

If it’s a photo puzzle, seal with Mod Podge or laminate before cutting.

💡 Possible Uses:

Personalized Gifts – Turn photos into handmade puzzles.

Kids’ Crafts – Educational puzzles with letters, shapes, or animals.

Branding – Add logos for promotional giveaways.

Decorative Sets – Art puzzle with engraved illustrations.

Events – Puzzle-based invitations or scavenger hunts.