I do stuff like that the Luddite way. I lay out the exact size design on paper. Glue the paper to plywood. Rough cut it out, then send down to the line. Perfect.
If I want more than one, trace the original on wood, rough cut, glue the original to the rough cut. Rout around that, and have a master that I can affix wood to and rout out copies up the wazoo, all perfect copies of the original.
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