Make a custom jigsaw puzzle, using lasers!

Supplies

Laser Cutter
Matboard (the thick kind, about 2mm)
Print of your design (use glossy photo paper for best results)
Mod Podge™
Clear coat (optional, but recommended)

Step 1: Mounting

Glue your print to the matboard with Mod Podge.

Apply a generous amount of Mod Podge to the matboard covering an area roughly the same size of the print. Place the print onto the Mod Podge and smooth it out by pushing firmly and working away from the center to remove any bubbles and excess Mod Podge.

Tips

You can also apply the Mod Podge directly to the back of the print and then press it onto the matboard. This can be more difficult with large prints but works well for small puzzles.
If you don’t use enough Mod Podge or smooth out the print well enough, the image will peel off the finished jigsaw pieces. If this happens, you can glue the image back down with a dab of Mod Podge.
The matboard may warp when the Mod Podge is drying which makes cutting more difficult. You can place the board on a flat surface and weigh it down to help prevent this.

Step 2: Clear Coating (optional)

Clear coating will give the puzzle pieces a professional looking finish and make them more durable. Simply follow the instructions for the clear coat of your choice.

The clear coat you use will depend on the type of paper your design is printed on. For smooth paper, like photo paper, a generic spray clear coat should work. For porous paper, like printer paper, make sure clear coat is explicitly rated for paper. Additionally, Mod Podge can be used as a clear coat on any type of paper.

Tips

Test the clear coat on a sample of the paper you’re using to ensure the two are compatible and give desirable results.
Use a spray clear coat for a smoother finish and to avoid brush strokes.

Step 3: Cutting

Load your soon-to-be puzzle into the laser cutter and start cutting! Choose “Matboard” for the material and input the total thickness of the puzzle.

If you haven't designed a file to cut the pieces, check out mine at https://www.thingiverse.com/thing:4854785

Tips

Ensure the matboard is flat before cutting or the
laser won’t be able to cut completely through some spots. If the matboard warped, bend it back before attempting to cut.
Test the laser settings on a small piece of matboard to ensure the laser cuts cleanly through.
The cutting process produces a lot of soot. You can clean of your puzzle pieces by wiping the edges with a damp cloth.