Recent work on boron-based neutron scintillator screens suggests these screens can offer superior performance when compared to commonly used screens. Borated neutron scintillator screens perform well in terms of light output (5–6 times greater than a standard Gadox screen) and detection efficiency (greater than standard LiF + ZnS screens). However, previously manufactured boron-based screens have exhibited non-uniform surface coating and poor mixture uniformity between phosphor and converter particles. The objective of this work was to evaluate newly fabricated scintillator screens to determine if enhanced fabrication methods produced a more homogeneous distribution between neutron converter and scintillation phosphor particles. Uniformity of scintillator material deposition was also inspected. This new iteration of screens appeared more uniform than previous generations with the new coating method improving surface chemistry and scintillator material homogeneity. Additionally, a new methodology for screen characterization, involving the correlation of a neutron image taken with a borated scintillator screen to X-ray computed tomography of that same screen, was demonstrated to elucidate a relationship between scintillator screen thickness and relative light output of the screen under neutron exposure. This method suggested that the ideal thickness of combined scintillator and boron-based converter material for this specific screen chemistry and fabrication method was ~ 150 µm to maximize light output of the screen.