Popsicle Stick Puzzles are gaining in popularity, with good reason. These customized puzzles are fun and easy to make! You just need some art (book illustrations or even something you created) Mod Podge, popsicle sticks, a paint or craftingbrush and a cutting tool.
Crafts and Art for Children has a great example with directions here: http://craftsandartforchildren.blogspot.com/2010/07/dinosaur-popsicle-stick-puzzle-start.html