Thanks for sharing nootropic. Have you paid your test engineers (your kids) for testing your design with games? You should include that in your cost too.
"I've never worked so hard for so little money."
I fully agree. But hearing you deal with tax makes me thing you did make some return from your work to worry about Uncle Sam. Good for you!
I personally don't like packing too much. I'm a bit OCD so I check too many times on perfectly packed kits and always fear I miss a part. I also reuse packaging materials from my own purchase so each package is unique (some had UK or HK stamps on them if you look carefully). It's time-consuming to come up with a different package each time. It's just me. I would mainly go through distributors to ease my brain.
So for those that turn our electronics hobby into a time-sucking, occasionally money-making, but always totally cool and self-rewarding business, good luck to us all!