The industrial journey from a single image to thousands of pieces

How Are Jigsaw Puzzles Made? (And Why One Piece Is Always Missing!) · 8:40 · Video: Explaining Everything · Watch at the source

In short: Ever wondered how manufacturers transform a flat picture into a complex, brain-teasing masterpiece? This video explores the manufacturing lifecycle of jigsaw puzzles, from initial design to the mechanical cutting process.

The production of a jigsaw puzzle involves selecting an appropriate image and converting it into hundreds or thousands of individual cardboard pieces. The core of this process is die-cutting, a method used to create specific shapes for each piece.

Beyond the mechanics of manufacturing, the video addresses the design logic behind piece shapes and investigates the common phenomenon of missing pieces in completed sets.

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