Here, I give a brief desciption of how I craft these matching puzzles with paper cardboard, where the patterns are printed on both sides of tiles. (For puzzles consiting of non-flippable tiles, 2 puzzles can be made at once.) Required tools are a paper bond (or woodcraft bond), a cutter knife and a ruler.
- Print two patterns onto papers with a printer whose ink has fastness against the water. A laser printer is sufficient.
- Prepare 2 paperboards of thickness about 1 mm for core material of tiles.
- Bathe both printed papers and paperboards in the water (or, only moisten the both sides of paperboards may be quick and sufficient). This prevents distortion of papers that come from moisture of the bond. It also make the crafting easier; without bathe, the bond will get dry quickly and one must work hurry.
- Glue the 2 printed papers with the paperboards for each. So, we get 2 paperboards of 1 mm thickness with patterns printed on both.
- Glue the resulting 2 paperboards; The result is a board of 2 mm thickness with both sides having printed pattern. (Make sure to meet the outline of tiles on both sides.)
- After the board is dried, cut it into tiles. (Actually, it is easier to cut the board before it is dried out.)
PVC (polyvinyl chloride) foam board (also known as 'FOREX') might be a better choice for core material of tiles because it is hard enaough to play puzzle, easy enough to cut, and unlike papers, it won't be deformed by moisture (you may need adhesive which can glue PVC and papers).
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