Step 1: Download and customize template
Edit the name and choose a cool font. You can add vector or raster images as artwork for your project. Each object can have a fill and a stroke around the outline. For all objects you want to engrave, use a fill but no outline. For all objects you want to cut out, use no fill but add an outline, and make sure the outline has width "hairline" in Corel Draw. The colors for each depend on your specific laser cutter settings, but I like to use pure black (#000000) for engraving and pure red (#FF0000) for vector cuts.
Step 2: Fire the Laser!
Depending on your material of choice, you might have to play around with the speed and power settings for the engraving and vector cutting. If you aren't using 1/8" thick material, you will have to adjust the size of the interlocking "fingers" between the three pieces.
I made it at TechShop, specifically the new Pittsburgh, PA location!
Step 3: Glue the pieces together
Here are a few more photos so you can get an idea of how they fit together. There is a little gap at the bottom of the front plate, and I might try to eliminate that in my next design.