All you need is a vector graphics editor such as Inkscape, Adobe Illustrator, CorrelDRAW, etc.
Inkscape is free.
Step 1: Find a Graphic
Find a black and white vector graphic or draw one yourself in Inkscape.
OpenClipart.org has lots of images http://www.openclipart.org/tags/b_w
Step 2: Elephant
How about this elephant!
Right click and download the file as an .svg
Step 3: Open It in Inkscape
Step 4: Edit Box
Round the edges by grabbing and pulling on the top right corner where the little red dot is.
Step 5: Chop It Up!
Cut it with the bezier tool or use shapes to add and subtract the joints.
Step 6: Submit It!
Go to Outfab.com and submit your file to be laser cut.
You are done with your FREE laser cut puzzle!
All you gotta do is wait for it to arrive in the mail.