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Hi Andrew
To minimise the effects of chipping, on the UNDERSIDE of each board, score the melamine surface with a Stanley knife along the line of cut. Then, for small, straight pieces I have used a fine tooth back saw to saw along the cutting line drawn on the upper surface (facing you as you saw).
The theory here is that looking underneath the board as you cut, the teeth will exit the board a very tiny fraction to the outside of the scored line, so that any chipping will be stopped at the scored line. Your piece of board that you want is on the inside of the scored line.
For curved pieces, I wonder if you could use a Router on a tangent arm?
Cheers
Dennis
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