Step 1: Component audit and deck count
When you place your game on our desk, we count every card, punchboard chit, and plastic miniature. We separate cards by format (Standard American 56×87mm, Standard CCG 63.5×88mm, Tarot 70×120mm, or Mini Euro 44×68mm). We note whether expansions will share the core box or require our multi-expansion storage crate.
Step 2: Caliper inspection under 0.1 mm precision
Using steel digital verniers, we gauge the exact thickness of your cards and punchboard sheets. Low-grade 250gsm cards flex differently than 320gsm linen-finish stock; our 100-micron archival sleeves add roughly 0.22 mm per sleeved card. A 300-card deck expands by 66 mm in depth when sleeved. We calculate that expansion before cutting any wood.
Step 3: Tray slotting and vertical drop test
Prototype interlocking 3mm Baltic birch trays are assembled directly from our component racks. We load your sleeved cards and heavy brass tokens into the wells, place the insert into your actual box, and turn the box on its side. We shake it gently. If a token slips out of its well or an acrylic lid shifts, we adjust divider notches by 0.5 mm increments.
Step 4: Formal specification sheet
Once tolerances are locked, we hand you a printed specification sheet itemizing exact sleeve counts, insert tier, token upgrades, and USD pricing basis. You can take this spec home or submit it directly through our inquiry form at inquiry.html for production scheduling.