For 11 years I've been wanting to turn my 'intricadoodle' style of characters into a puzzle. At the time, I couldn't wrap my head around the production process. But now with having access to a laser, I gave it a shot as a gift for JibJab's CEO, Gregg Spiredellis.
Original sketch:
Making it vector in Illustrator: 
Under the laser:
Mounting the back:
