Use machined in PCB guides, rather than pillars.
 
Try to ensure that all machining is done from one side of the plastic to reduce costs.
 
Try and allow a minimum radius of 1mm on all holes and cutouts.
 
Allow the maximum possible corner radius for label recesses. This then
allows us to use a large cutter, and therefore the machining time and cost is reduced.
 
Allow a minimum of 0.3mm on each side of a label recess, to ensure adequate tolerances, between the label and the recess itself.
 
Ask us if you are in any doubt as to the feasibility of any designs you have. It is easier to change ideas and thoughts at the outset, rather than mid way through a design.

 
DON'TS

 

Put label recesses, or holes near to folds, 5mm is an absolute minimum.
 
Put PCB grooves lower than 4mm from the internal base of the box.
 
Use black fine grain material for lids or other folded parts, just face panels. It is very prone to scratching.
 
Screen print on anything other than fine grain material.
 
Have pillars any shorter than 4 mm.