Reduce screw usage?

[benz145]

I adore these boxes! After printing several (and wanting to print even more), I'm wondering if there's a way to alter the design to reduce the reliance on screws. I've been making 5x4 stacking boxes which require 18 screws each. Compared to plastic the screws are obviously quite expensive and they also add a disproportionate amount of time to assembly. While I understand that these boxes are designed to be "rugged," I would love to see a redesign (or an added option) to reduce the screw usage.

I imagine the lowest hanging fruit for reducing screw usage would be the screws that are used to keep the stacking latches in the folded up position. It should be possible to make a lip or bumps in the printed design that would serve the same purpose.

Doing this would save one screw per stacking latch; in the case of a 5x4 box that means reducing from 18 screws to 14 screws, or a reduction of 22%.

The next lowest hanging fruit would likely be the screws in the lid that the stacking latches (from the above box) hang onto. I have to think there's a way to create a protrusion of sufficient strength that would allow the top box to attach just as securely without using another screw.

This would also reduce the screw usage by another 4 screws, dropping the screw count of a 5x4 box down to 10 screws, a 44% reduction.

And if you managed the above, ostensibly you could use nearly the same design to create a protrusion for the draw latches to catch onto, dropping the screw count from 10 to 8, for a total reduction of 55%.

With all of this, I could make twice as many boxes with the same number of screws!