0.125" acrylic about 12" x 12"
Draw shapes in coreldraw:
use various shapes tools in coreldraw to draw other shapes within the material square/rectangle, I did: rectangle, circle, ellipse, pentagon, parallelogram, letter J, star, arrow, square
cut the shapes on the laser cutter (print, set printing options, close lid, press play)
Analysis: I failed to keep the ctrl key held down while enlarging shapes which resulted in non symetrical shapes(although to the eye they are symmetrical). this resulted in a better/more challenging puzzle which holds the interest of my 4 year old longer.
The Kerf of the laser (amount vaporized) was surprisingly small resulting in a good loose/snug fit.
I made it at TechShop