With this Covid-19 Stay-At-Home thing, and with inspiration from evansd2 (Layered Offset Box), here are two layered boxes using round toothpicks for alignment between layers. Evansd2 attained better alignment precision using brass rod, but toothpicks were available and easy to work with.
Holes were cut in all layers for alignment except for top and bottom layers. Alignment pits were engraved in these pieces so no alignment devices were invisible for the closed boxes. Outside diameter is 3.2 inches.
The Covid-19 thing: My Glowforge has been a real lifesaver for driving fun projects and producing amazing precision-made objects. I’m a really old guy in a retirement facility and so appreciative of the machine, the support from the company, and especially the community. Thank you all for inspiration and help.
I have found barbecue skewers to be great for many such applications. They are bamboo so quite strong over their length. Not exactly precision but close enough for anything I have done. I have the common 1/8", and less common 1/4" diameter and some cut square if I don’t want rotation.
They make exceptional wooden hinges and I suppose alignment pins as they are far more consistent over their length than toothpicks.