Using the tiles in the file copy and paste the letters needed so you have enough, then layout your family's names connecting the letters like you would in a game of Scrabble. In some cases you may not be able to connect all the names, if that happens use the star piece to connect the names. Add at least one each of the special bonus pieces where they look good. You can reference an image of a real Scrabble board if you want them to be placed accurately, but it it doesn't really matter, just make it look good.

Delete all the unused letters and then make a copy of the ones for your family's name. Arrange them into a grid that's 3 letters wide and as tall as needed but don't make any of the letters touch. Give them at least 2mm on all sides. Place this grid next to the main board so that both will fit on a 300mm wide piece of wood. Select the letters that you actually laid out on the board for your family's names and set them to score mode. This will be your template on where to glue the letters when you're done. Also if you didn't fill the full width of the board then grab the letters, group them, and then center them horizontally so they don't look lopsided.

Edit the family surname on both pages to match your family name. You may need to adjust the position of the “The” and “Family” portions if your name is shorter so they look good. Just make sure they're centered so they don't look lopsided. Once you have typed your surname do an “Offset” in XCS of 1mm and then delete the original text, this extra thickness will allow the letters to cut cleaner and be less fragile. 

 

Copy the bonus pieces to a new canvas. Ensure the red is set to cut and the blue is set to engrave. Leave the originals in place on the first canvas, and set to score just like the letters, so you know where to place them. 

You're going to need to paint the wood for the bonus pieces ahead of time. The “Double Word Score” and Star pieces are pink, the “Double Letter Score” is light blue and the “Triple Letter Score” is a cyan blue color. Wait for the paint to completely dry then cut and engrave them. 
 

I recommend doing 2 or 3 of each just to be safe in case they get mishandled or the engrave works better on one than the other. 

You will also likely need to set the laser power higher than you normally would for the engrave so that it gets through the paint and actually darkens the wood. If it doesn't look good at first don't move anything and you can run multiple passes until it reaches the proper darkness. 

Use a piece of birch or basswood for the main board and tiles so that it's roughly the same color as real Scrabble tiles. Make sure to frame it so that everything fits within the edges. I used 6mm birch for mine, but anything from 3-6mm will look fine. Technically real Scrabble tiles are 4mm thick, but 4mm thick wood is a bit difficult to find. 

I typically start with a score and engrave pass, with air assist turned off, then a cut pass with the air assist turned to max. 

I used walnut plywood for the frame and surname, but you could use any color you like or even paint you'd prefer. The idea here is to have contrast from the base. If you're going to paint it then it will look better, and be easier, if you paint the wood ahead of time. The thickness of the wood should be the same as you used for the base so that it's the same height as the tiles.

Once everything is cut you can glue it all together. If you want to seal or oil the pieces then do it before this step and allow it to dry. You'll use the score on the main board to align the surname and the tiles. 

Attach one of those saw tooth hangers or a string/wire to the back so you can hang it on a wall. It's also small enough that if you wanted you could attach one of those picture frame stands and put it on table or shelf instead.