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Originally Posted by GeeTwo
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We used Tetrix Max in 2011 when it was just called Tetrix, since that was what everyone got to help build their minibots (before everyone wised up to the One True Way To Build A Minibot that called for just the motors and bronze bushings and battery). I imagine there are a few valid uses for it on an FRC machine, but they are few and far between.
4901 used VEXpro Versaframe gussets last year on their robot, paired with our Worseaframe self-drilled tubing. Worked out pretty nicely for us. In years prior with 2815, we'd often build with nothing but 1x1 square tubing, angle aluminum chopped for gussets, and a ton of pop rivets. 80% of what was above those bumpers could be found at Lowe's, and it netted three banners in two seasons.
There are certain extruded shapes that lend themselves to robots, such as Bosch FMS, 80/20, or the new-for-2015 Rev line. We used FMS this year since we're supported by Bosch, but if I had to go and put cash into a system I'd probably give Rev a good look since it accepts more standard hardware and has a very simple process to get linear motion working. In all my experiences though, this gets heavy after you start adding on connectors--great for prototyping and mockups, limiting in production. (Rev uses flat gussets that are less of a weight issue, since it was designed with our applications in mind where FMS and 80/20 get used in industry a whole bunch.) Generally speaking, I'd recommend tube over these lines unless linear motion was a must-have. (Vex now has a linear motion kit for Versaframe, but I haven't had a chance to get up close with it yet.)
Not as much of a kit, but since you have CAD expertise coming in I might also suggest sheetmetal construction. The ability to place holes and bends precisely where you want them is nice, and odds are pretty darn good that there's a company within an hour's drive capable of doing it. Even if you have to pay a few hundred bucks for their services, it may save you the frustration of trying to figure out how to string something together out of COTS items. (Would've saved me a lot of frustration in 2012 with our shooter.)
Hope this helps!