About a year ago I took one of my favorite picture of my son and I and I laser engraved it onto a black piece of acrylic. Once i had the picture onto acrylic and to the size I prefered, I then vector cut it out like a puzzle. I thought it would be fun to make my own puzzle with my own hand picked photograph. Boy was I right it was a lot of fun to take apart and put together again. It made for a great conversation piece. To add a little color to the picture I laser cut a few different frames of acrylic to fit perfectly around that outside of the puzzle and it worked and looked great!
What we have found to work the best in displaying these puzzles is an easel because it allows you to display the puzzle with all the pieces without having to lay it down flat.
With our Epilog Zing Laser it is almost impossible to share with anyone the setting to raster the image onto the black plastic. All images are slightly different and all I can say is trial and error and years of doing these images has been our best guidance. What I will say however, the program PHOTOGRAV is outstanding. Anyone wanting to laser photos onto a substrate needs this program. Vector cutting is a different story. The Speed we used to cut through 1/8" Acrylic was 24, the Power was 100, and the Frequency was 5000.
Other variations that one could do would be to use other shapes besides rectangle for the puzzle. Heart shaped or oval shaped would look outstanding as well.