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We've used rapid prototyping to build demo models of some robot components for the past two seasons. It's a very brittle, rough, starchy kind of model that's not really good for actual robot parts, but it helps the students and engineers visualize how the thing is going to go together.
It would be great to have something like what you're proposing at a competition, although I'm not sure if the material would be considered an "exotic material" (and thus be illegal) under the current parts rules.
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...Only a few people are awake and they live in a state of constant total amazement. -JP Shanley, Joe vs. the Volcano
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