These puzzles are so easy and so simple to make. You basically just need some thick card stock and some peel and stick foam rubber sheets.
First, print the picture you want to make into a puzzle on the card stock. If you want to use mine click here for the file. The words I used were: pig, wig, big, dig, pin, in. We are using readingbear.org to learn phonics so these words are from the first "short i" presentation. (I highly recommend this free program especially if your child is little like mine.)
Then peel off the back of the foam sheet...
...and stick the card stock with your picture on to the foam.
Cut out your puzzle pieces with an xacto knife or razor blade.
And voila! If you want something more durable you could print your picture on sticker paper and then stick your paper on card board. For me, the foam sheets are great because they are so easy to slice but it still feels somewhat durable.