[blaze8902]

I'm also interested in the data from your compression testing. If you'd be willing to share it, I'm sure many people would appreciate it. Potential fabric damage tests would be great as well, as Ether asked.

Oh, and a comment about the wheels you're using: Have you considered using pneumatic tires? We saw many of them last year for Frisbee launchers, and I think they might work well for your case. Both the wheel and the ball will compress, and it should mesh well together, and the rubber tire material should work well with the ball fabric also. I think teams ran into some balancing issues, but they worked well in the end, generally. Cheng Shin 200x50s is what we prototyped with last year.