I had some boxes I needed made. Knowing I had a laser cutter, I did a fast google search and found MakerCase (see note in a few paragraphs in italics). I quickly downloaded a custom-sized box with box joints, and slapped it through the paces. It couldn't cut deep enough, and repeated attempts failed to stay lined up.
I then realized that a $50 sheet of acrylic was a pittance less than a package from SendCutSend in acrylic. So, off the DWG's were sent, and processing/mailing times were waited.
Apparently, the MakerCase file is on the outside of the cut line. This means that the box joint cuts will have a minimal overlap. I corrected this using a file on the joints to fit it, so make sure you fit it up BEFORE you glue it.
I tried to purchase a thin acrylic adhesive, but that got lost in the mail somewhere, so I ended up using e6000 cement from a local hardware supply chain.
This cement is terrible - it immediately starts to congeal, so be aware that long cuts (like I had on my box) will start setting up before to finish applying the cement. It is also very stringy - so it will be messy.
It should be noted that it is still a workable option for fast prototyping, or for custom one-off boxes.
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