This was my first 3D assembled laser-cut project using Ponoko. The aim here was to create a desktop business card holder which would fit on a single P1 sheet of acrylic.
It took me a while to work out the dimensions and interlocking shapes on paper - then two tries at laying out the design in Inkscape. The first time I inadvertantly ended up with the interior measurement I had intended as the exterior measurement - so it was back to my sketching out dimensions again.
The design would work with any material which is 4.5mm thick - as this is what I have allowed for in the interlocking joins. I have used the transparent acrylic, as I wanted the focus to be on the contents, not the container.
I also used a single cut between the pieces, so there is a tiny lazer-width gap where they meet. My next step is to get ahold of a solvent-based adhesive such as IPS Weld*On #4 or #16 to attach them all together.