50 – Making a Wooden Laser Cut Jigsaw Puzzle (28:52)

The Lightblade Learning Lab with Russ Sadler

The Lightblade Learning Lab is a series of videos that Russ did for Thinklaser Limited based on using the Lightblade 4060 Laser Cutting and Engraving Machine. Thinklaser’s Lightblade 4060 has a 400 x 600mm bed size and was supplied with a 60W EFR laser tube. In this session, Russ shows us how he would manufacture a laser cut jigsaw puzzle.

Laser Cut Jigsaw Puzzle - Acrylic base
Laser Cut Jigsaw Puzzle – Acrylic base

Contents

  • Using 3mm thick, Baltic birch plywood as a substrate.
  • While the process of cutting a jigsaw puzzle looks simple, getting it to look neat, is the challenge.
  • Physical problems to be faced.
    • What base should be used?
    • Using a pre-cut jig mount with absolute mode
    • Need to save a template .RLD file
    • Making permanent fixing holes in the machine
  • Engraving a picture on the surface
  • Set-up and cutting of pre-cutting template
  • Cutting of template for easy removal of cutting fumes.
  • Cutting using the jig did not give the expected results
  • Trying on a honeycomb bed
    • Cover remaining honeycomb to get more suction through the cut area.
    • Not a great result on the back.
  • Cutting a photographic puzzle onto 3mm thick frosted acrylic
    • Using 3M 467MP adhesive film
    • Extraction is vital as all the smoke needs to go out through the back of the job
    • Dust present on the surface (from the picture?) but it does wipe off.
    • Summary – Suggested that use satin black acrylic

My thanks go out to Tom at Thinklaser for giving permission to embed these videos on this site. If you are looking for a new laser machine from a quality supplier, then I would suggest you check out their website: www.thinklaser.com.

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This video is the last of the Lightblade Learning Lab Series. Why not try out one of our other video series such as:

The Tangerine Tiger Series where Russ has purchased a new 500 x 300mm, 50W laser machine from eBay with a view to modifying and upgrading it. In fact, he rips out the glass laser tube and high voltage power supply and replaces them with an RF laser source and PSU from Cloudray. Find out how the expensive RF laser source compares to a glass CO2 laser tube and prepare to get your hands dirty!

The Fiber Laser Series is all about Russ’s adventures and investigations with a 30 watt fibre laser, loaned to him by Dean at Lotus Laser Systems. If you are looking to engrave metal, without the fuss of using coatings such as Thermark, Cermark or Molybdenum Disulphide spray, then this is the series for you.

The Lightburn Software Series is probably the best generic laser cutting software available (I use it for almost all of my laser work). This series has tutorials, hints and tips as well as the occasional speed comparisons between it and RDWorks. My thanks to the team at Lightburn for allowing me to embed their videos.

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Check out The Concise RDWorks Learning Lab Series that condenses all of Russ’s work into an easy to follow encyclopaedia of laser knowledge.

Video Resource Files of Making a Wooden Laser Cut Jigsaw Puzzle

A4 Puzzle Jig.dxf

A4 Puzzle Template.dxf

There are no resource files associated with this video.

External Resource Links of Making a Wooden Laser Cut Jigsaw Puzzle

www.thinklaser.com

www.rdworkslab.com

What can a laser cutter cut?

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Transcript of Making a Wooden Laser Cut Jigsaw Puzzle

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Transcript of Making a Wooden Laser Cut Jigsaw Puzzle

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[Music]

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well welcome to another LightBlade

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Learning Lab today the title of the

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piece tells it all we’re going to use

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some of this a for Baltic birch plywood

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which is three millimeters thick to try

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and make some puzzles

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now jigsaw puzzles are on the surface of

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it quite simple to make once you’ve got

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the design sorted out but manufacturing

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it so that is a really nice neat piece

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of work is much more difficult so today

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I’m going to show you first of all the

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problems that we’re going to have and

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then we’re going to try and find a

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solution now so try and find a solution

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because I’ve not done this before and so

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we’re going to jump into something very

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new which I’m moderately confident will

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solve the problem now let’s forget the

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details of the puzzle itself at the

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moment and look at the physical problems

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that we’re going to face I don’t think

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that’s necessarily a good idea to use

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this table to cut this to cut this

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puzzle on because first of all all the

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pieces will fall down inside some of

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them will get trapped in here and as

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they get trapped in here what will

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happen is the cut as it carries on will

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mark the pieces that are trapped in here

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you know you’ve just got no control of

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where the pieces are going to fall that

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tells us that before we start we’ve got

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to retain the puzzle in one flat plane

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complete while it’s being cut so that

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leaves us with this second option which

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is the honeycomb table when you’re

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cutting wood you can see what happens on

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the end look we’ve got all sorts of

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brown muck in here which when we pass

Transcript of Making a Wooden Laser Cut Jigsaw Puzzle (Cont…)

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the laser beam over the top of it

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it’s going to blow up horrible foods at

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the back and mark the back of the job so

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let’s just test this as an idea to start

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with right well I’ve got a 2-inch lens

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in here here’s the material that we’re

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going to be using and it’s a nice white

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of Baltic birch plywood I’ve got a two

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inch gallium arsenide lens in here which

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will be one of the standard lenses that

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you’re supplied with

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and I’m just going to run a test square

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up in this corner I’m running at about

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25 millilitres a second on full power

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[Music]

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and I think as you can clearly see we’ve

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got all these marks around the pieces

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which is where the laser beam has jumped

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over these small pieces of honeycomb

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although this solves one problem ie it

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keeps all the pieces in one plane and

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together if you’re happy to accept this

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on the back of your puzzle because it’s

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only for your own use

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then go ahead use your honeycomb table

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but to me that’s totally unprofessional

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and the wrong approach if you’re trying

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to sell bespoke puzzles for example to

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somebody you certainly won’t want all

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these marks on the back of your pieces

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very unprofessional so we need to start

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looking for something as an alternative

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backing material my first reaction was

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hey let’s have something that doesn’t

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cause smoke something that won’t burn

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and here we are look we’ve got a piece

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of polished granite this doesn’t burn we

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won’t get any blowback off the surface

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so I’m going to leave the extraction off

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so that we can see what happens

Transcript of Making a Wooden Laser Cut Jigsaw Puzzle (Cont…)

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[Music]

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not huge amounts of smoke there’s a good

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reason for that

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[Music]

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although it’s a lovely nice clean cut on

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the top as you can see

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let’s take a look underneath well the

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reason why we didn’t have too much smoke

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coming upwards was because it all went

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downwards we mostly damage the surface

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here but look we’ve got all sorts of

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sticky brown stuff on it which is the

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fumes that have actually vaporized on

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this cold surface as they’ve been blown

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through the job and look those same

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fumes which are in a liquid sticky form

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have also they’ve done a huge amount of

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damage red on the outside of our cut so

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very very very unsatisfactory so that’s

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not a solution to our problem we’ve got

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to find a way of getting the fumes

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cleanly out the bottom of the job so

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that they can get extracted away and we

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don’t get any reflections off of pieces

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of material that are supporting the job

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that sounds like an almost impossible

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task when it comes to cutting jigsaw

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puzzles which are whole load of separate

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pieces yeah we need sky hooks to hang on

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and I’m afraid I don’t know how to make

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sky hooks but I am gonna have a go at

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trying to make something which is a

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closed alternative to a sky book now

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kill the guards function that basically

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is made up of two small pieces base

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plate and a top plate I’m going to

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assembly this onto this top plate rather

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than onto the base plate so speed is of

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the essence why are we doing this part

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okay so here’s our assembly if we look

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through it we should see that we’ve got

Transcript of Making a Wooden Laser Cut Jigsaw Puzzle (Cont…)

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a clear passage way underneath here for

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the air to flow through underneath this

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plate and as expected it’s a nice snug

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fit for a piece of plywood we’ve got a

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solid surface behind here so we’re going

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to produce exactly the same effect that

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we did here if we’re not careful we’re

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going to get debris which condenses on

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this surface and runs out behind the cut

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we need to make sure that the fumes that

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we produce during cutting go right the

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way through the job and then we can put

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air underneath here remember where it’s

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a nice clear passageway and get sucked

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away so somehow we’re going to have to

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pre-cut this in the shape of the puzzle

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so that the track when we cut the puzzle

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the foods past right the way through

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here to do that means that we’ve really

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got to bolt this fixture down onto the

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table which is nice and solid so that

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once we’ve cut the track in here we can

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immediately replicate that

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when we come to cut the puzzle we don’t

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want the puzzle to be cut over a

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different track than the cuts that we’ve

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pre produced in here now to do that we

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can’t rely on any external location so

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we’re going to have to use a feature

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that’s available on this machine a

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feature called absolute mode and let me

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explain what absolute mode is for those

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of you that have never used it before

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well here I’ve drawn a sheet of a4 size

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material and across the center line here

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I’ve drawn two holes just here and here

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now these are going to be the fixing

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holes that I used on my jig I’m going to

Transcript of Making a Wooden Laser Cut Jigsaw Puzzle (Cont…)

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have to put these holes into the base

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plate of my machine so that whenever I

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put this jig back into the Machine I

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will know exactly where the coordinates

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where the program is going to run

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because I have changed this feature here

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called position from current to

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something called absolute coordinates

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now what that means is you will not be

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able to use the the origin button on

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your machine so what I’m going to have

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to do eventually is to draw our puzzle

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picture on top of this template because

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this is a template that is going to

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allow me to always replicate exactly the

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position of this piece of a4 material

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and my program will always work with

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exactly the same coordinates that I

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programmed and run in this machine so if

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I set my piece of iturra

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at the top here it will always run up

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here so positioning of this is not super

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important it’s conveniently wherever you

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want it on your machine bed I dropped

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mine here and that’s where it’ll be

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forever when I use absolute coordinates

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so that means that you must save this

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picture here as an r OD file because

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this is going to become a template for

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any other program that you

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to run on a for material in this jig or

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another jig that you might want to

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design around the same fixing holes so

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once we’ve got the fixing holes in the

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machine we’ve effectively got a new

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reference position which we can

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replicate every time I’m going to find a

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way to put these holes into my machine

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bed exactly where I’ve drawn them and to

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do that what I’m going to do is to put

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the holes on a different layer so let’s

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put them onto a red layer okay so we’re

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now come up to the top here and we’ll

Transcript of Making a Wooden Laser Cut Jigsaw Puzzle (Cont…)

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set the red layer to cut some holes

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seven millimeters yeah Polish power yes

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that’ll do so it’s a cut layer

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okay now the black layer will check the

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black layer and it says here do you want

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an output well the answer is no and it

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doesn’t matter what any of the other

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settings are now so these spacings here

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are roughly 50 millimetres apart on this

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grid so one two three it’s just over a

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hundred and fifty millimetres about 160

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millimetres up from the bottom edge of

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the table I’ve got a strip of material

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here acrylic it doesn’t matter what it

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is this is happens to be about five

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millimetres thick so roughly 160

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millimetres up from the bottom edge of

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the table we’ll set that across there

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like that

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[Music]

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put a little bit of tension on it

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is to make sure that piece of plastic is

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not going to move and there we go that’s

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00:11:16.16 –> 00:11:21.680
pretty solid now as you can see the

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table has got a small amount of movement

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in it this way but I purposely made it

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00:11:25.43 –> 00:11:30.950
so that it’s got nothing in it sideways

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but what we can do is to remove the

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clearance in the table backwards and

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forwards with that small peg so now

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we’ve got a completely solid table no

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movement so we need to just set the

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focus correctly run this program all I’m

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going to do is going to get two holes

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punched through the material just there

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[Music]

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simple as that

Transcript of Making a Wooden Laser Cut Jigsaw Puzzle (Cont…)

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except I’ve now got to get these little

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pieces out click we now remove our

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cutting template and I’ve got an m4 tap

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here now hopefully I’ve got nothing

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underneath there to get in the way of my

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screws I just check I can now screw my

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fixture down to the table with two

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screws and I know exactly where my sheet

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of a4 material is going to be relative

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to the zero zero of the machine and

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whenever I run this program it will

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always be in exactly the same place now

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obviously you can’t do it if you’ve got

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one of these floating around and it only

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works if you can get an absolutely

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00:12:52.12 –> 00:12:57.150
stable base to bog it too

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we’re going to create our own picture

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[Music]

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nobody shouldn’t complain about the

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lovely lady like a holiday

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[Music]

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so we know exactly where this a4 sheet

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is and any pattern that we draw on it

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will be the program will be referenced

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to zero zero in the corner there now

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this is everything that you want to know

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about the a4 puzzle on one sheet of

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paper so we need to zoom out and you’ll

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see what I mean

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so here we’ve got the jig which we don’t

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need delete here we’ve got my basic

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general arrangement which we don’t need

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and we will delete here we’ve got a

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layout of what the top plate looks like

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with all the little reference squares in

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it so it’s just a check delete here

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we’ve got the puzzle pattern which we

Transcript of Making a Wooden Laser Cut Jigsaw Puzzle (Cont…)

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don’t need at the moment so we delete

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that and the only thing we’re left with

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is that is this jig preparation template

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now I’m going to leave the two holes in

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because everything is symmetrical I’m

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going to mark that and make that a group

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I know that I’ve put the puzzle

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symmetrically in this a4 frame I’m going

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to mark just the puzzle and not the

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frame I’ve got to put it into a group

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click on that and we’ll turn that into a

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blue Lane I’m going to put handles on

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that blue layer now and we are going to

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press the shift key and we’re also going

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to highlight this other group

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and I can now use these alignment tools

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at the top here to align at first of all

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00:14:51.259 –> 00:14:56.629
horizontally and watch this jiggle now

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there we go

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00:14:56.629 –> 00:15:00.809
so it’s now jiggled out of line to its

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00:14:59.189 –> 00:15:02.459
own reference square but that doesn’t

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00:15:00.809 –> 00:15:04.439
matter because what we’re doing we’re

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00:15:02.459 –> 00:15:06.509
lining the patent up with this reference

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00:15:04.439 –> 00:15:09.360
square we’ve put our pre cutting

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00:15:06.509 –> 00:15:14.610
template into the correct position on

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the jig we can now delete this frame

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00:15:14.61 –> 00:15:20.730
here because we don’t need it we’ve got

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00:15:17.579 –> 00:15:23.999
everything that we need just here we

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00:15:20.73 –> 00:15:26.670
don’t want anything black to cut so

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00:15:23.999 –> 00:15:31.230
we’ll check the black layer and we’ll

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00:15:26.67 –> 00:15:33.509
make sure that it says is output no ok

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00:15:31.23 –> 00:15:34.079
we now check the parameters for the blue

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00:15:33.509 –> 00:15:38.459
layer

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he’s output yes speed 20 millimeters a

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second that’s good blowing yes cut yes

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and power eighty percent that’s good

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okay now we need to make sure just be

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00:15:49.139 –> 00:15:52.470
doubly doubly sure the last thing you

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00:15:51.059 –> 00:15:54.660
check is that you’ve got absolute

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00:15:52.47 –> 00:15:57.149
coordinates set down the corner here now

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00:15:54.66 –> 00:15:59.429
we’ve set the focus up already to six

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00:15:57.149 –> 00:16:00.530
and a half millimetres reference to this

Transcript of Making a Wooden Laser Cut Jigsaw Puzzle (Cont…)

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surface here

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[Music]

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okay so I’ve removed all the pieces and

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you can see what we’ve got there we’ve

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got a two milk gap between every single

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00:16:17.029 –> 00:16:22.070
piece and I hope that’s gonna be enough

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00:16:19.58 –> 00:16:24.710
of a gap to let all the smoke at the

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00:16:22.07 –> 00:16:25.970
bottom of the job without coating the

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00:16:24.71 –> 00:16:29.300
bottom of the job with this horrible

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00:16:25.97 –> 00:16:30.890
brown gunk that we get by any other

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00:16:29.3 –> 00:16:32.870
means that we can try and produce this

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00:16:30.89 –> 00:16:34.700
puzzle right so we’ve got our fixture

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00:16:32.87 –> 00:16:36.260
bolted back in the machine we know it’s

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00:16:34.7 –> 00:16:38.240
the right way around because I put some

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00:16:36.26 –> 00:16:40.130
location reference marks at the back

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00:16:38.24 –> 00:16:42.020
corner there to make sure that we didn’t

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get in the wrong way around because

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00:16:42.02 –> 00:16:47.390
although the jig is symmetrical the

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pattern in the puzzle is not and it only

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00:16:47.39 –> 00:16:54.470
works this way round we’ve got our

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lovely lady that we can cut I have got

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00:16:54.47 –> 00:17:00.650
an alternative for those that like

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00:16:56.42 –> 00:17:03.650
aeroplanes when we engrave this it

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00:17:00.65 –> 00:17:05.810
tended to curve this way now I would

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00:17:03.65 –> 00:17:08.079
have liked to have put it in the jig

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00:17:05.81 –> 00:17:10.610
that way but it meant that the middle

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00:17:08.079 –> 00:17:13.670
would be standing up and slightly out of

347
00:17:10.61 –> 00:17:15.199
focus this has a really snug fit in here

348
00:17:13.67 –> 00:17:17.420
which is great although it’s dished

349
00:17:15.199 –> 00:17:19.400
we’ve pulled the corners down so it’s

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00:17:17.42 –> 00:17:22.160
all back to flat again now we must

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00:17:19.4 –> 00:17:27.800
remember to set the focus to a different

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00:17:22.16 –> 00:17:31.510
position this time so six and a half

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00:17:27.8 –> 00:17:31.510
lots of smoke coming out underneath

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as I mentioned right at the beginning of

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this video cutting the puzzle is the

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00:17:36.46 –> 00:17:42.460
easy part is preparing to cut the puzzle

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that’s the difficult at this moment in

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time we’ve got all the pieces suspended

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00:17:45.1 –> 00:17:49.570
by their ends it’s only when we start on

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00:17:48.159 –> 00:17:52.450
the next phase which is the cross

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00:17:49.57 –> 00:17:57.269
cutting here all of a sudden the pieces

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00:17:52.45 –> 00:17:57.269
start releasing stress

Transcript of Making a Wooden Laser Cut Jigsaw Puzzle (Cont…)

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now we don’t at the moment seem to have

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00:18:01.32 –> 00:18:07.409
come across any inclusions or voids

365
00:18:04.529 –> 00:18:09.299
within the material if we did they would

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00:18:07.409 –> 00:18:11.669
have produced some probably horrible

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00:18:09.299 –> 00:18:13.619
black marks on the surface now this

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00:18:11.669 –> 00:18:17.249
puzzle may only be a hundred and forty

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00:18:13.619 –> 00:18:20.539
pieces but my guess is because all the

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00:18:17.249 –> 00:18:23.429
pieces are square there’s one piece of

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00:18:20.539 –> 00:18:25.409
blue there is one clue that you haven’t

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00:18:23.429 –> 00:18:27.480
got which is basically some of the

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shapes of the material the other thing

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00:18:27.48 –> 00:18:31.739
is all this stuff is shades of brown

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00:18:29.34 –> 00:18:34.889
which makes it very difficult to match

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00:18:31.739 –> 00:18:37.139
up so I suspect this is going to take

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00:18:34.889 –> 00:18:38.800
somebody quite a long time to rebuild

378
00:18:37.139 –> 00:18:43.380
this puzzle

379
00:18:38.8 –> 00:18:43.380
the piece of clear perspex underneath

380
00:18:45.54 –> 00:18:49.029
now slide the whole puzzle out

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00:18:47.26 –> 00:18:51.099
[Music]

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00:18:49.029 –> 00:18:54.609
and the reason I’ve slid this out onto a

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00:18:51.099 –> 00:18:57.000
piece of a4 clear Perspex is so I can

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00:18:54.609 –> 00:18:59.580
turn it over

385
00:18:57.0 –> 00:19:02.630
and we can have a look at the back well

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00:18:59.58 –> 00:19:05.150
I have to say then it’s not

387
00:19:02.63 –> 00:19:07.190
entirely successful I look around each

388
00:19:05.15 –> 00:19:09.650
knob we’ve got a little pocket of gas

389
00:19:07.19 –> 00:19:11.750
which has been trapped because we

390
00:19:09.65 –> 00:19:14.480
haven’t got a clear passage for our

391
00:19:11.75 –> 00:19:16.190
smoke to exit below the cut so unless we

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00:19:14.48 –> 00:19:20.210
can find a solution for that

393
00:19:16.19 –> 00:19:21.990
which means cutting away big chunks in

394
00:19:20.21 –> 00:19:25.030
lots of places

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00:19:21.99 –> 00:19:28.240
[Music]

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00:19:25.03 –> 00:19:30.430
we we probably would do just as well to

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00:19:28.24 –> 00:19:33.640
do it on them honeycomb tighten again

398
00:19:30.43 –> 00:19:37.330
it’s cold up at the corners but not

399
00:19:33.64 –> 00:19:38.360
badly but what would do were put half a

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00:19:37.33 –> 00:19:40.340
dozen magnets

401
00:19:38.36 –> 00:19:43.600
[Music]

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00:19:40.34 –> 00:19:43.600
reasonably flat

403
00:19:46.62 –> 00:19:54.049
there’s not a lot of grip on Honeycomb

404
00:19:51.38 –> 00:19:56.820
no gain all we need to do is to measure

405
00:19:54.049 –> 00:19:59.000
roughly a hundred and fifty millimetres

Transcript of Making a Wooden Laser Cut Jigsaw Puzzle (Cont…)

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00:19:56.82 –> 00:19:59.000
in

407
00:20:01.56 –> 00:20:06.120
there and that’s where we’re going to

408
00:20:03.87 –> 00:20:08.640
start now we covered the honeycomb with

409
00:20:06.12 –> 00:20:12.150
as much paper as we can to try and block

410
00:20:08.64 –> 00:20:14.400
off the airflow going down that way

411
00:20:12.15 –> 00:20:16.380
hopefully what we’re trying to do is to

412
00:20:14.4 –> 00:20:21.330
get as much air flow pulled through the

413
00:20:16.38 –> 00:20:23.690
cuts as we possibly can since the heart

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00:20:21.33 –> 00:20:23.690
milk

415
00:20:30.52 –> 00:20:33.930
[Music]

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00:20:35.149 –> 00:20:43.019
so from the front side that looks a

417
00:20:38.58 –> 00:20:44.490
half-decent puzzle picture let’s have a

418
00:20:43.019 –> 00:20:46.639
look see what it looks like from the

419
00:20:44.49 –> 00:20:46.639
back

420
00:20:50.0 –> 00:20:54.740
well I suppose you could always spray it

421
00:20:51.98 –> 00:20:56.419
white couldn’t you and that’s the reason

422
00:20:54.74 –> 00:20:58.370
why we started this whole project of

423
00:20:56.419 –> 00:21:00.049
saying it’s going to be very very

424
00:20:58.37 –> 00:21:03.860
difficult to get the back of these

425
00:21:00.049 –> 00:21:06.200
puzzles clean now our friend is a bit

426
00:21:03.86 –> 00:21:14.809
sad to say but I think there’s only one

427
00:21:06.2 –> 00:21:16.789
place for this and that’s in the bin now

428
00:21:14.809 –> 00:21:20.240
this was the only one that gave anything

429
00:21:16.789 –> 00:21:24.129
like half decent results and as I said

430
00:21:20.24 –> 00:21:28.460
where we had a clean run across the job

431
00:21:24.129 –> 00:21:30.919
we got virtually no marking and it was

432
00:21:28.46 –> 00:21:34.370
only when we went across this way that

433
00:21:30.919 –> 00:21:36.440
we had marks and it was mainly on the

434
00:21:34.37 –> 00:21:40.220
wall it was literally only caused by

435
00:21:36.44 –> 00:21:44.720
these tongues now what that means is you

436
00:21:40.22 –> 00:21:49.610
could possibly solve this problem by

437
00:21:44.72 –> 00:21:52.309
making two fixtures one with braces that

438
00:21:49.61 –> 00:21:55.309
run across this way and one with braces

439
00:21:52.309 –> 00:21:58.519
that run across that way so you do half

440
00:21:55.309 –> 00:22:00.350
the puzzle like this and then you do the

Transcript of Making a Wooden Laser Cut Jigsaw Puzzle (Cont…)

441
00:21:58.519 –> 00:22:03.150
other part for the puzzle in the second

442
00:22:00.35 –> 00:22:05.850
jig like that

443
00:22:03.15 –> 00:22:09.150
now if you’re that enthusiastic about

444
00:22:05.85 –> 00:22:11.490
making decent quality puzzles then there

445
00:22:09.15 –> 00:22:14.340
is a solution I’m not going to do it

446
00:22:11.49 –> 00:22:16.650
because I’ve proved half the problem has

447
00:22:14.34 –> 00:22:18.840
been resolved and I can see what the

448
00:22:16.65 –> 00:22:21.150
other half had the other half could be

449
00:22:18.84 –> 00:22:24.150
resolved but that still leaves us with

450
00:22:21.15 –> 00:22:26.130
the problem the cuts are a significant

451
00:22:24.15 –> 00:22:28.920
part of the picture

452
00:22:26.13 –> 00:22:30.840
they are predominating this may well be

453
00:22:28.92 –> 00:22:32.490
a lot less dominating if we were to do

454
00:22:30.84 –> 00:22:35.640
this with a coloured photograph because

455
00:22:32.49 –> 00:22:38.460
it would take your eye away more from

456
00:22:35.64 –> 00:22:41.640
these marks so perhaps I’ll have one

457
00:22:38.46 –> 00:22:44.400
more try at trying to create a nice

458
00:22:41.64 –> 00:22:47.160
puzzle and I think there’s a possibility

459
00:22:44.4 –> 00:22:51.000
that we might be able to do it here we

460
00:22:47.16 –> 00:22:54.210
are with a photographic print and what

461
00:22:51.0 –> 00:22:56.850
I’ve got here are two things first of

462
00:22:54.21 –> 00:23:01.610
all I’ve got some special double-sided

463
00:22:56.85 –> 00:23:05.630
and very high bond strength tape by 3m

464
00:23:01.61 –> 00:23:08.190
and you can see it’s called 3m 476 MP

465
00:23:05.63 –> 00:23:10.350
now you can buy this in sheets it’s

466
00:23:08.19 –> 00:23:14.340
pretty expensive because it’s a very

467
00:23:10.35 –> 00:23:18.240
thin film adhesive and and it’s an

468
00:23:14.34 –> 00:23:21.330
acrylic adhesive that cuts very well now

469
00:23:18.24 –> 00:23:25.410
we’ve got to apply this to the back of

470
00:23:21.33 –> 00:23:31.679
the picture and we’ll do that by peeling

471
00:23:25.41 –> 00:23:34.550
off the front clear plastic now we’ll

472
00:23:31.679 –> 00:23:34.550
fold it over like this

473
00:23:35.5 –> 00:23:43.710
so that what we can do that holds their

474
00:23:38.47 –> 00:23:48.460
end off while we fit this end nicely

475
00:23:43.71 –> 00:23:50.830
I’ve cut this already to a4 size and I

476
00:23:48.46 –> 00:23:53.350
know that it fits perfectly onto a four

477
00:23:50.83 –> 00:23:56.380
and now I should be able to just wipe

478
00:23:53.35 –> 00:24:01.120
that up there like that and stick that

Transcript of Making a Wooden Laser Cut Jigsaw Puzzle (Cont…)

479
00:23:56.38 –> 00:24:03.789
onto the top and now to make sure that I

480
00:24:01.12 –> 00:24:05.740
don’t get bubbles under it what I’m

481
00:24:03.789 –> 00:24:07.480
going to do is gradually peel this pick

482
00:24:05.74 –> 00:24:12.429
pull this piece off from underneath here

483
00:24:07.48 –> 00:24:14.260
like this while at the same time I’m

484
00:24:12.429 –> 00:24:16.720
running my finger backwards and forwards

485
00:24:14.26 –> 00:24:19.539
along here to make sure that we push all

486
00:24:16.72 –> 00:24:24.010
the air out as we go now what I’ve got

487
00:24:19.539 –> 00:24:26.409
here is a piece of it’s a piece of

488
00:24:24.01 –> 00:24:28.049
acrylic three millimetres thick this

489
00:24:26.409 –> 00:24:30.610
happens to be a piece of frosted acrylic

490
00:24:28.049 –> 00:24:34.270
now acrylic is not going to cause as

491
00:24:30.61 –> 00:24:37.030
many fumes as wood we’ve got to get the

492
00:24:34.27 –> 00:24:38.409
backing tape off of here and again we’re

493
00:24:37.03 –> 00:24:42.710
doing the same thing we’ll fold that

494
00:24:38.409 –> 00:24:46.169
over so that we can line everything up

495
00:24:42.71 –> 00:24:47.849
approximately and this time we’re going

496
00:24:46.169 –> 00:24:53.509
to use some clean kitchen towel so that

497
00:24:47.849 –> 00:24:53.509
I don’t damage the gloss on the paper

498
00:24:56.63 –> 00:25:01.620
we’re going to cover the honeycomb again

499
00:24:58.98 –> 00:25:05.010
with paper so that we get plenty of

500
00:25:01.62 –> 00:25:07.320
extraction straight through the cut and

501
00:25:05.01 –> 00:25:09.990
again we’re going to set our datum

502
00:25:07.32 –> 00:25:12.700
[Music]

503
00:25:09.99 –> 00:25:15.040
down in the middle here

504
00:25:12.7 –> 00:25:19.150
that the origin because we’re in current

505
00:25:15.04 –> 00:25:22.390
mode remember their black lines across a

506
00:25:19.15 –> 00:25:24.640
colored photograph will actually be less

507
00:25:22.39 –> 00:25:28.330
distracting than those black lines

508
00:25:24.64 –> 00:25:31.000
across a brown image now we’ve got

509
00:25:28.33 –> 00:25:33.070
fuller assist on and I’m trying to

510
00:25:31.0 –> 00:25:36.280
extract as much air as I can out the

511
00:25:33.07 –> 00:25:39.460
back because it’s absolutely essential

512
00:25:36.28 –> 00:25:42.610
that we don’t get any white debris up on

513
00:25:39.46 –> 00:25:45.570
top of our job all the smoke must go out

514
00:25:42.61 –> 00:25:45.570
the back of the job

515
00:25:50.86 –> 00:25:56.940
[Music]

516
00:25:52.7 –> 00:26:01.190
now comes the tricky bit getting it off

Transcript of Making a Wooden Laser Cut Jigsaw Puzzle (Cont…)

517
00:25:56.94 –> 00:26:01.190
the table

518
00:26:02.8 –> 00:26:08.819
[Music]

519
00:26:09.96 –> 00:26:17.740
look at the madness on the top there

520
00:26:13.41 –> 00:26:20.110
oh my goodness me the dust has come up

521
00:26:17.74 –> 00:26:26.540
but it does wipe off easily

522
00:26:20.11 –> 00:26:26.540
[Music]

523
00:26:28.67 –> 00:26:33.090
and surprisingly now if it has not

524
00:26:31.18 –> 00:26:40.820
damaged the picture

525
00:26:33.09 –> 00:26:40.820
[Music]

526
00:26:40.94 –> 00:26:44.760
just keep wiping it until the tissue

527
00:26:42.89 –> 00:26:47.490
goes clean

528
00:26:44.76 –> 00:26:50.610
okay so we’ve juggled it now on to our

529
00:26:47.49 –> 00:26:52.390
piece of paper let’s see what it’s like

530
00:26:50.61 –> 00:27:07.690
on the back Sheree

531
00:26:52.39 –> 00:27:11.450
[Music]

532
00:27:07.69 –> 00:27:14.030
well I would say that that’s almost

533
00:27:11.45 –> 00:27:15.620
presentable on the back there well in

534
00:27:14.03 –> 00:27:17.390
this session I hope that I’ve steered

535
00:27:15.62 –> 00:27:22.340
you away from all the possible pitfalls

536
00:27:17.39 –> 00:27:24.110
of making a wooden puzzle now a wooden

537
00:27:22.34 –> 00:27:26.630
puzzle is something that really is

538
00:27:24.11 –> 00:27:28.760
reserved for a clean machine like a

539
00:27:26.63 –> 00:27:31.760
jigsaw which is why it’s called a jigsaw

540
00:27:28.76 –> 00:27:33.559
puzzle laser cutting is not a very good

541
00:27:31.76 –> 00:27:36.410
process for working with wood or

542
00:27:33.559 –> 00:27:38.870
cardboard because we produce far too

543
00:27:36.41 –> 00:27:42.010
many fumes which will condense and

544
00:27:38.87 –> 00:27:44.770
damage your pieces

545
00:27:42.01 –> 00:27:47.410
what we have finally shown you is the

546
00:27:44.77 –> 00:27:49.660
way in which you can succeed by

547
00:27:47.41 –> 00:27:52.780
producing a really nice contrasting

548
00:27:49.66 –> 00:27:55.860
colour picture which takes your eye away

549
00:27:52.78 –> 00:27:58.510
from the black lines that are on here

550
00:27:55.86 –> 00:28:00.100
you have to do it from the front so you

Transcript of Making a Wooden Laser Cut Jigsaw Puzzle (Cont…)

551
00:27:58.51 –> 00:28:02.860
need to make sure that you get your

552
00:28:00.1 –> 00:28:05.010
parameters set up well although we have

553
00:28:02.86 –> 00:28:08.380
got some black marks on the back here

554
00:28:05.01 –> 00:28:12.000
into a few places those black marks

555
00:28:08.38 –> 00:28:15.040
would not show at all if you change this

556
00:28:12.0 –> 00:28:18.070
material from either clear or frosted

557
00:28:15.04 –> 00:28:21.700
acrylic as I’ve got it there into a

558
00:28:18.07 –> 00:28:24.640
satin finished black now put the satin

559
00:28:21.7 –> 00:28:27.010
finish facedown on the honeycomb table

560
00:28:24.64 –> 00:28:30.360
and you will probably hide any marks

561
00:28:27.01 –> 00:28:32.530
that happened to be on the back here so

562
00:28:30.36 –> 00:28:35.050
now you have the secret to making

563
00:28:32.53 –> 00:28:39.190
personalized puzzles and I will pass

564
00:28:35.05 –> 00:28:40.870
this puzzle program on to think later so

565
00:28:39.19 –> 00:28:44.170
that you can download it for yourself

566
00:28:40.87 –> 00:28:45.660
well thanks again for your time and I’ll

567
00:28:44.17 –> 00:28:50.160
see you in another session

568
00:28:45.66 –> 00:28:50.160
[Music]

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