Do you think puzzles marketed on toy stores are not healthy because of the plastic material ? you are right indeed. If you feel bad about the idea that your kid contact with unhealthy plastic materials, you had better craft your own puzzles with fabrics.
You can craft any fabric version of puzzles available on stores within short times depending on the design you want to craft. The samples seen in the picture were crafted from fabrics and hook and loop fasteners. The puzzle parts can be fastened through the hook and loop fastener.