[PhantomPhyxer]

I am happy to see that most Teams are using Aluminum. It is light an strong when used properly. I would suggest that if you are useing Solidworks. You should go the next step an have one of your mentors teach you Stress Analysis using your computer model. Finite Element Amalysis does not optimize a part but you can iterate on a solution by just changing the thickness of the material and re-running the problem.

When designing think of an "I" Beam. The top and bottom web are very critical in bending. The center web between the top and bottom flanges carry the shear. So, if you keep the flange the same thickness but seperate it by a larger distance then the the moment of inertia is increased and the bending strength increased.

If you ask a more specific question I will try to answer it.

You might also try in using a Ballistic grade of Aluminum like 5083 that is work hardened.

Norman Collier