Following up - for my 16:9 monitor I can create a custom resolution of 768 x 432 that retains the display's aspect ratio. Adding 3 pixels for the border, I define the dimensions of the DMD as
dmd_width = 771
dmd_height = 195
The dots are uniformly sized and spaced and displays edge to edge on the monitor. Unlike before, I can't overscan. At these dimensions the size of the border is minimized.
My display can also manage 256 x 144, but the resulting image was too dim.
At 512 x 288, the image is still dim but might be tolerable if you always play in a darkened room.
768 x 432 was acceptable
If the pattern holds then the following resolutions might also work. I haven't put it to the test because I actually want a low resolution.
1024 x 576
1280 x 720
1536 x 864 - this would be the highest resolution for my display and should produce the brightest image while keeping the dots uniform.
1792 x 1008 - this would be the highest resolution for a 1080p display
2560 x 1440 - if you are running a really expensive display for a DMD monitor
3840 x 2160 - 4K UHD would work
7680 x 4320 - 8K UHD would work too but I wouldn't expect that kind of display to fit in any cabinet except for one built for a pinball god
I think for those running something different than 16:9, it would be a matter of matching a horizontal resolution from the options above and adjusting the height until each "dot" is a square, that is that each DMD pixel has the same width and height.
[EDIT] - For the sake of curiosity I tested at 1536 x 864 and it did not work as anticipated. The image was the correct aspect ratio if I define width=1539 and height=387 but the image is small with large black bars drawn at the sides and top and bottom.
So, 767 may indeed be the current maximum horizontal with ddraw=0.
I'm running a Pin2K style cab. Going edge-to-edge and maximizing the image to reflect on the playfield works for me. The image is dramatically larger than a size that matches a standard display. I don't have to fit the image inside a bezel.
If I had a traditional design with a DMD panel, I would test combinations of image sizes and display resolutions and take very good measurements prior to cutting the bezel.
If you cut the bezel first, you can certainly turn on ddraw and stretch the image to fit any size but at the risk of introducing artifacts, tiling and banding, that can detract from the experience.
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Edited by Carny_Priest, 23 June 2014 - 04:15 PM.