[JamesCH95]

Well, 5052 (~30-35ksi yield strength) will be half or less of the strength of 7075-T6 (68-73ksi yield strength). 5052 in similar in strength to lower grades of steel (A36, 36ksi YS for example) whereas 7075-T6 is similar in strength to alloy steels like 4130 (70-75ksi YS). I would be suspicious that plasma cutting would wreck the T6 temper in 7075 thus making it weaker, but 5052 in not heat-treatable so it would not lose any strength. That, along with it's superior formability, low cost, and wide availability, is probably why the shop suggested 5052 over 7075.

If you want to drop weight I would suggest using thinner steel with a higher strength, or more accurately evaluating your actual strength requirements and sizing material accordingly. I suggest this because I have learned that steel cuts *much* better with plasma than aluminum does. I think it's because steel is much less thermally conductive than aluminum is, so there's a smaller kerf angle and less slag. But that's beside the point...

Using a thinner alloy steel would be particularly effective if you heat-treated, say, 4130 or 4140 to ~Rockwell C22-27ish, to pick a hardness range that's very strong (something like 130ksi-145ksi YS) and still somewhat ductile and tough. Your plasma cutting sponsor might have heat-treating furnaces and could just throw your parts in (mounted on fixtures) with their parts. This may be huge overkill though...

Just my $0.02 on your predicament.

Edit: FWIW most AM kit frame elements (c-rails, the axle mounts from 2010, etc) are folded 1/8in 5052 aluminum and all hold up very well to FRC abuse, so making drive pods with the same material and thickness seems reasonable to me.