There are too many variables for anyone to answer this question. I know you provided a lot of info, but everyones room conditions, rack designs, heater wattage, and type of thermostat are different.

Yes it is safe to router grooves in melamine/particle board. This is how I heat my cages. I router the grooves into each shelf to give belly heat. It will giev you a much bigger gradient than using back heat. I router extra grooves every 1.5 inches. That way depending on the species, room temp, and desired hot spot temp, I can add or take away heat cable as needed.

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