Step 2: Cutting the frame
Because I was using the Epilog laser cutter, I needed to do a few different tests to find out what setting I'd need to cut through the two layers of foam core at once, without setting anything on fire.
I did my samples and recorded the settings, as you can see below. I only cut out the inner part of the frame, because the laser melts the foam inside. Since I wanted the outside edges to look like notebook paper, I used a hobby knife to cut those.
Since I had enough foam core to play with, I cut out two frames (each two thicknesses). This gave me some wiggle room to screw one up completely if needed. Which I did.
Hey, here's a handy file for you to download so you can cut your own!