MDF Photoframe Mat

[duke149]

I have tried a number of times to get a Mat made to hold a small LCD screen in a photo frame.

I tried twice with plastic, then gave up and tried 3 times with MDF.

The issue I have is that the screen is perfectly square. Any small deviation in my cutting is obvious and looks terrible.

The plastic I used a cutting wheel on a Dremel trying twice. Both attempts looked terrible.

MDF I used
- Scroll saw. My line looked perfect, until I held it against the screen. I then saw it was all over the place.
- CNC ( I have calibration issues that I have no idea how long it will take to fix )
- Sharp knife and ruler

I thought about using a router with guides, but I don't think it will get into the corners properly.

Does anyone have any recommendations on how I can cut this square out perfectly?

Is there a material better than MDF or plastic I should use? I am trying to avoid using cardboard.

[elanjacobs]

Can't think of anything that will beat a CNC for accuracy.
What size are you after? If it will fit in a flat-rate PostPak I can cut it on the CNC at work and send it.

[ian]

a router with guides will give you perfectly straight lines and right angles
the corners will be rounded, but that's easily fixable with a sharp chisel.