How Jigsaw Puzzles Are Made? (Mega Factories Video)

How Jigsaw Puzzles Are Made? (Mega Factories Video)

A jigsaw puzzle is a tiling puzzle that requires the assembly of often oddly shaped interlocking and mosaiced pieces. Typically, each individual piece has a portion of a picture; when assembled, the jigsaw puzzle produces a complete picture.

Most modern jigsaw puzzles are made out of paperboard since they are easier and cheaper to mass-produce than the original wooden models. An enlarged photograph or printed reproduction of a painting or other two-dimensional artwork is glued onto the cardboard before cutting. This board is then fed into a press. The press forces a set of hardened steel blades of the desired shape through the board until it is fully cut. This procedure is similar to making shaped cookies with a cookie cutter. The forces involved, however, are tremendously greater and a typical 1000-piece puzzle requires a press that can generate upwards of 700 tons of force to push the knives of the puzzle die through the board. A puzzle die is a flat board, often made from plywood, which has slots cut or burned in the same shape as the knives that are used. These knives are set into the slots and covered in a compressible material, typically foam rubber, which serves to eject the cut puzzle pieces.

New technology has enabled laser-cutting of wooden or acrylic jigsaw puzzles. The advantage of cutting with a laser is that the puzzle can be custom cut into any size, any shape, with any size (or any number) of pieces. Many museums have laser cut acrylic puzzles made of some of their more important pieces of art so that children visiting the museum can see the original piece and then assemble a jigsaw puzzle of the image that is also in the same shape as the piece of art. Acrylic is used because the pieces are very durable, waterproof, and can withstand continued use without the image fading, or the pieces wearing out, or becoming frayed. Also, because the print and cut patterns are computer-based, lost pieces can be manufactured without remaking the entire puzzle.

Video Credit: www.ravensburger.com & www.clementoni.com

This video is part of our β€˜How Everyday Things are Made’ series. To watch other video of the series click on this link: https://youtube.com/playlist?list=PLmHzFWJOOSAoI1i6R-YMCdVIDmMDjBV40

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Watch some of our other interesting manufacturing videos:
How Plywood Is Made In Factories?

How LUXURY Rolls-Royce Cars Are Made ?

How Pencils are made in Factories?
https://youtu.be/XpzJNVCfy2U

50 Comments

  1. Bill Hamilton on October 19, 2023 at 10:03 pm

    nice but how were they made 75 years ago



  2. citizen on October 19, 2023 at 10:04 pm

    I like puzzles



  3. Road Rash on October 19, 2023 at 10:08 pm

    I’d like to tackle that huge puzzle & see how long it takes to finish working at least 6-8 hrs daily, or more…I love puzzles & seeing how fast I can finish them…more challenging, the better…



  4. Wayne Warmack on October 19, 2023 at 10:09 pm

    It’s a DIE, not "dice"!



  5. electronron1 on October 19, 2023 at 10:09 pm

    I don’t want to brag but I finished a puzzle in a week and the box said 6 to 12 years.



  6. Cindy Rissal on October 19, 2023 at 10:11 pm

    It seems as though modern jigsaw puzzles are kinda lame compared to older ones. The older ones had very unique, differently shaped pieces…the challenge was to find the right shape plus the right color when looking for a puzzle piece. Now the pieces are all the same size & shape. I know, the colors still have to be in the proper place, but somehow it seems as though a small but fascinating element of the puzzle is gone…



  7. Todd Lueders on October 19, 2023 at 10:11 pm

    somebody needs to look at the written explanation – it’s full of grammatical and other mistakes, run-on sentences etc



  8. Mahier on October 19, 2023 at 10:13 pm

    i think it’s time i make my own puzzle



  9. A Human Person on October 19, 2023 at 10:14 pm

    Sad we no long need companies like this, with the internet just order a Pizzle and it is sent to you home.



  10. Robert Becker on October 19, 2023 at 10:14 pm

    Up until today, I only bought 2 puzzels full price…new…cuz they are expensive. Now I can appreciate their expense.



  11. Stu West on October 19, 2023 at 10:16 pm

    You’d have to really hate life to waste time doing a puzzle.



  12. Kathy Miller on October 19, 2023 at 10:16 pm

    βœοΈπŸ€πŸ”―πŸ˜‡πŸ‘πŸ§„πŸ•ŠοΈπŸ”­πŸŽ‡πŸŒπŸŒπŸŒŽπŸͺπŸŒ πŸ‡ΊπŸ‡ΈπŸ¦…Holy Psalm 91 Jesus and KathrynMiller say Thankyou for sharing βœοΈπŸ€βœοΈπŸ€βœοΈπŸ€πŸ€πŸ€πŸ¦…πŸ‡ΊπŸ‡Έ



  13. avi8r66 on October 19, 2023 at 10:19 pm

    The only interesting part is how the die for cutting is made and used… The rest is no different than any other printing job. And that one interesting part was skipped through in about 15 seconds.



  14. luis gonzalez alvarez on October 19, 2023 at 10:20 pm

    nice music



  15. person two on October 19, 2023 at 10:20 pm

    Does the same die cut many different puzzles? IOW, could you end up with Snow White and Bambi together if you bought both puzzles and started at opposite ends?



  16. Rob Appeldorn on October 19, 2023 at 10:21 pm

    You left out the part where they take out the last puzzle part and throw it away.



  17. Bedogg on October 19, 2023 at 10:21 pm

    I figured they’d probably move to some kind of laser cutter instead of making a master die for such things



  18. Home tuition for CBSE & ICSE (SB Sethi)πŸ“ on October 19, 2023 at 10:22 pm

    2 hrs a day for such senseless work πŸ₯±πŸ₯±



  19. Christopher Sanchez on October 19, 2023 at 10:24 pm

    I wanted to see who spends the time bending the blades to cut those puzzles.🀯



  20. Nina Jiron on October 19, 2023 at 10:25 pm

    I would love to see how the puzzles are broken apart before they are bagged.



  21. Vito Certosino on October 19, 2023 at 10:25 pm

    Somebody should write a novel about all the lost pieces of puzzles in the world being gathered together to miraculously compose a gigantic, clumsy , misshaped ,odd numbered, cursed Frankenstein-like puzzle that’s impossible to finish for everybody apart from the Chosen One who will be able to complete and reveal ” The Image ” (obviously without a box or any other clue)



  22. Francina Manning on October 19, 2023 at 10:28 pm

    Every step was shown except how the die cuts themselves are made. I would like to see that.
    Were puzzles ever featured on the program "How It’s Made"?



  23. Abi Gail on October 19, 2023 at 10:28 pm

    Jigsaw puzzles nowadays come with an instruction manual?



  24. bluetigerbee on October 19, 2023 at 10:29 pm

    Where is my missing piece?



  25. Zambik is king on October 19, 2023 at 10:29 pm

    Imagine dropping that puzzle



  26. Clare Ravenwood on October 19, 2023 at 10:29 pm

    Never had a puzzle with an assembly guide. Usually just something about the company and other products.



  27. gary v on October 19, 2023 at 10:32 pm

    How was it done before computers?



  28. Dewey Mugyoo on October 19, 2023 at 10:34 pm

    Only white people work at the puzzle factory. Hm.



  29. Thad on October 19, 2023 at 10:37 pm

    No verbal explanations = πŸ‘ŽπŸ½



  30. papillon dorΓ© on October 19, 2023 at 10:37 pm

    I.,am a grandma and i spend 2 hours everyday
    To make jigsaw puzzles . Thank’s a lot.



  31. raterus on October 19, 2023 at 10:38 pm

    Instruction Manual:
    Step 1: Attach two adjacent pieces together.
    Step 2: If unattached pieces remain, repeat Step #1.



  32. Craig Stjohn on October 19, 2023 at 10:40 pm

    how do you, determine, the size of each piece of puzzle?! & how do you know what type of pictures you’ll use?? πŸ™βœοΈπŸ’’πŸ’ŸπŸ€—



  33. David Wilson on October 19, 2023 at 10:41 pm

    I missed the machine that removes one piece from each package and hides it



  34. NelsaN ART on October 19, 2023 at 10:41 pm

    Still sometimes you get some pieces stuck together!
    You have no time to make a machine that completely separates all piece?



  35. Steve Roark on October 19, 2023 at 10:41 pm

    I like the one time? She drew in the thing?



  36. NaZha on October 19, 2023 at 10:41 pm

    Life of Germans like a puzzle. Make simple things complicated.



  37. NelsaN ART on October 19, 2023 at 10:43 pm

    Do people even make any of the new Disney movies posters?



  38. AMATEUR Author on October 19, 2023 at 10:44 pm

    do you make larger pieces for 5 and 6 year old.



  39. Bill Hamilton on October 19, 2023 at 10:44 pm

    nice but how were they made 75 years ago



  40. SiriusGD on October 19, 2023 at 10:45 pm

    I love Ravensburger’s quality and fitment but Buffalo has more fun pictures. I would buy more Ravensburgers if they had more fun pictures. 1,000 piece.



  41. southerndeth on October 19, 2023 at 10:46 pm

    I just wanted to hear, "Elves in trees." This was disappointing.



  42. Ultimate Basses on October 19, 2023 at 10:47 pm

    Try the US made Dowdle Costco 1000 piece puzzle.



  43. Kim Jacobson on October 19, 2023 at 10:54 pm

    I Love Putting apuLES TOGETHER IVE DONE A 1000 PIECE PUZZLE ITS INTRESTING TO SEE HOW PUZZLES ARE MADE I LIKE PUTTING RHEM TOGETHER IN MY FRWE RIME KNOW M



  44. ꧁RadicalRick꧂ on October 19, 2023 at 10:54 pm

    *I use both my laser cutter and Cricut Maker 3 for making my puzzles.*



  45. Alex Paulsen on October 19, 2023 at 10:55 pm

    The last jigsaw puzzle I did was quite certainly just a photograph that had been digitized into a painting, the details were too specific for it to be an artist’s rendition. My guess is there’s a lot less effort going into jigsaw puzzles than they pretend here. I also suspect it wasn’t printed in a special manner with somebody pretending he can measure a difference in quality with a just magnifying glass, and the factory it was made in wouldn’t have had such a high ratio of white folk.

    Not to mention the tooling likely wasn’t unique, there’s many thousands of jigsaw puzzles all cut with the same tooling, as demonstrated by artist Tim Klein from Vancouver, Washington who has been able to mix and match pieces of jigsaw puzzles cut from the same die for his artwork.



  46. Idk Idk on October 19, 2023 at 10:56 pm

    I paused it on accident just as the word quality was disappearing. It made it so the y was really small. I thought it was smart little joke until I was re-watched it. 1:35

    πŸ€”πŸ˜œπŸ’



  47. Sam Williams on October 19, 2023 at 10:57 pm

    This is all very good but how do those diemakers get those dies? Do they just go down to Walmart and buy them?? Probably not.



  48. guyontheblackchair on October 19, 2023 at 10:58 pm

    For crying out loud they are not "dice". They are dies.



  49. Vera Rolim on October 19, 2023 at 10:59 pm

    πŸ’–πŸ‘πŸ»πŸ‘πŸ»πŸ‘πŸ»πŸ‘πŸ»πŸ‘πŸ»πŸ‘πŸ»πŸ‘πŸ»πŸ‘πŸ»πŸ‘πŸ»πŸ‘πŸ»πŸ‘πŸ»πŸ‘πŸ»πŸ‘πŸ»πŸ‘πŸ»πŸ‘πŸ»πŸ‘πŸ»πŸ‘πŸ»



  50. Sweet JR Ewing on October 19, 2023 at 10:59 pm

    ‼️‼️Incudes instructions …What ta Hell πŸ€£πŸ˜‚πŸ˜…πŸ€·πŸΌβ€β™‚οΈ