[Clem1640]

We've used carbon fiber/plywood composites for years for electrical panels and other flat panels which require strength/stiffness/light weight. Yes I know that carbon fiber is electrically conductive, but there are fixes around this.

This year, our ball pickup frame is fiberglass pultrusion, with the ends filled with an epoxy-carbon fiber composite to prevent collapse when tightening through bolts. The technology comes from Gdeaver (see earlier post this thread). This construction provides a ball intake which flexes elastically when stressed, rather than breaking or permanently deforming.

We've learned that in some cases, we can replace steel components with 7075 Aluminum (similar tensile strength, but still soft). Also that if welding is unnecessary, either 7075 or 2024 Al provides high strength (again, if there is no abrasion). 6061 Al remains the only real aluminum option for welding.

1640 uses a range of polymers on our robots. Polycarbonate and polypropylene are big ones, but nylon, acetyl, polyurethane, polyethylene and PMMA are used as appropriate. Don't get me started talking about rubber.

I love materials!