Make each letter/number out of a pattern, I.E. unconnected dots. Meaning the computer has no way of knowing that a dot is part of a letter other than pattern recognition (which they don't have yet.) Then the usual distortions and random lines.
How you do this is the challenge.
EDIT: Also, bonus points for patterns of different shapes, and try alpha transparency on the characters (on the edges or the whole character), so they merge with the background.