PurposeTo develop an image processing approach for jigsaw puzzle assembly.Design/methodology/approachFirst, pixels are extracted from the jigsaw puzzle blocks to calculate their rotation angles and centre coordinates. Second, a template matching method is employed to recognise each block and its orientation.FindingsA robot‐based jigsaw puzzle system is established; and an effective image processing approach for assembly is developed.Practical implicationsAutomatic assembly lines that assemble parts with the same shape, but random position and angle, can employ the jigsaw puzzle assembly method.Originality/valueAn effective image processing method for jigsaw puzzle assembly is presented in this paper. The validity of the method is proved by analysis and experiment.