I have seen mixed cardboard and clear plastic packaging of products so tuff that one has to use metal cutters to open such as those sold in Costco. I think the packaging people can make it on the cheap given sufficient volume. Isn't just a folded cardboard in a box with some cards ? The little plastic houses and stuff, those can be made by some companies that recycle plastic.. typically made in USA.
Check out Smarter Every Day YouTube for the Smarter Scrubber series about building a BBQ grill scrubber exclusively in the USA. It’s a great series, but it shouldn’t be that hard.
If the cost of 3d printing can come down, this should solve this dilemma.
At what scale? How is 3d printing at the scale of a boardgame you can sell nationwide different then the current manufacturing methods to create these materials?