The process in a nut shell is to draw up your design in a graphics program, cut it out by using a laser cutter, glue the pieces together and attach a saw tooth hanger on the back. Then you have a custom made awesome gift to give out. I'm going to walk through the process that I followed for the Mario collage that I made as a late Christmas gift for a friend. In addition you can also paint the individual pieces, stain them, frame the whole piece or hang it as is.
If you like any of these designs I have the finished projects for sale on my Etsy right now. If there is enough interest in a design I'll post the files that I used to cut them up there too or send it out. Message me if you have any questions about it!
Now on to the step by step guide to create the Mario Collage: