“Box creep” is what happens when inserts swell, lids lift, and trays no longer seat after repeated punches. Customers rarely notice on day one; they notice on day sixty when the shelf sags and nobody wants to teach the game again.
The three-pass rule
We punch every punchboard twice on separate evenings, then bag components using only the supplied bags. If anything forces an extra tuck or a corner fold, we photograph it and usually pass on the line.
Tray tolerances
We measure vertical play with a simple slip gauge: if stacked tiles rock more than two millimetres in the long slot, we mark the SKU as “needs aftermarket insert” in our internal notes — and we tell you on the product page when that is the honest verdict.