Step 1) First thing done for this project is to find a rounded font that has a full body, I used the Junegull font that is a free download. I started with first letter for sizing then I typed out the full name. This name was then spaced to the value of 1 to give room between each letter for the next step.

Step 2) Now the letters need a place for the little fingers to remove the puzzle pieces, this was done with creating a .750 in circle with the insert button. a circle was needed for each letter and was placed in a line just off each letter about half way.

Step 3) Now it was time to copy and paste the letters of the name so they were exactly the same. Once the second copy of the name was made all of the top name and circles were high lighted and the combine feature was used to unite the circles to the letters.

Step 4) Now the backing was needed where the letter cut outs would be. i created a rectangle but used the radius feature to round off the corners so it was easier to handle. Once this was sized and in place I copied it and pasted a second backing. One will have letters cut ot and the other would be solid.

Step 5) Once the laser machine finished cutting all the pieces from the 2 different colors the assembly is straight forward. The the blue piece with the name cut out is glued to the solid piece of yellow. Then the individual letter can be placed within the puzzle, the finger spots allows the pieces to be removed again.