First off, thanks for your patience (and tweet) I was able to see this and reply!
The placement for the hinged area and the edges when closed will always have some give/play as it is a part that opens. It will vary on assembly but shouldn't be more than what you described (1 to 2 millimeters).
Also in regards to the plexi having some play/movement. It is due to the design of the plexi that it also has some give; due to us wanting to have an easy to replace art template system. Traditionally on a control panel, the buttons would sandwich the artwork and snap down over the artwork area instead of being able to go through it. There are solutions to alleviate this but it involves getting plexi made by a vendor like Art Hong (
http://tek-innovations.com/arthobbies/) to get TE2 plexi. I've used his in the past and it is a solid solution and stays firm.
If there are any other questions feel free to PM me!