Nice job Ryan. I've tried doing the puzzle pieces on a rotary axis laser, and the problem is the same; you have tons of small parts to assemble. Even worse than being a normal puzzle, it becomes a 3 dimensional puzzle that's harder to put together. The pieces can only interlock in one directon, so it's a nightmare to get everything to fit also. I think your approach is more straightworward here. The parts can fit tighter if the programmer allows for the beam kerf, but it's a tricky thing to do since some of the cuts are male and others on the same piece are female. Thinner stock will also get a tighter fit, but that means more pieces! I hate when that happens! One approach that might help is to cut all the pieces of one wood in a single block; in other words, leave them attached together on the part outside the pen that will be turned off. This will allow better alignment and fewer parts to keep track of. You would have a single strip around 1" wide and 5" long that has 5 puzzle shaped holes coming out of it. When the opposite wood pieces are glued in, they will be perfectly spaced and aligned. On the unused outer section you could even program holes for toothpicks to exactly align the blocks.