I was inspired by the opening screen of the XTool Creative Software. Always seeing that dinosaur wood puzzle made me want to create something similar. The end result is this 74-piece Welsh Dragon Puzzle.
The size of your tab cuts is EXTREMELY CRUCIAL! If the cuts that link the pieces of wood together are too wide, it's extremely difficult putting the puzzle together. The puzzle will easily fall apart. You want to have the puzzle pieces fit together tightly, but not too tight.
Even though your wood may be advertised as 3mm thick, it may actually be different. Even in the same package of wood, the sheets will be different thickness.
The key is to find a couple sheets the same thickness. Then adjust your pattern to find the right size (wide) tab cuts. I suggest running a few test cuts to find the right tightness.
I've provided the project files for two thicknesses of wood: 2.1mm and 2.4mm. These will help you get started. Adjusting the tab size is as easy as loading the project file, then resizing everything to get the correct tab size you need. Sure, your puzzle will either be larger or smaller, but it won't be much of a difference. However, smaller makes the puzzle harder to put together.
The attached project files have been optimized to fit the puzzle onto two 12" sheets of wood. Actually, it only takes 1½ sheets of wood.
Hopefully, you've got your laser cleaned and making clean cuts. The puzzle looks better if there's no scorch marks.
Load your wood - set your distance - mark your processing area - align your project.
When ready, cut away then repeat for the second board. Watch out for those little pieces. They are easy to lose, or they fall into the honeycomb.
If you have a good tightness in your cuts, putting the puzzle together is easier. The first time you put it together, you'll probably need to constantly look at the attached photos to see how the parts go together.
For a permanent decoration, you can glue the pieces together. But there's no need.