Sheet metal and FDM. LOTS AND LOTS of sheet metal. Oh, and anodizing, powder coat paint.
Usually we do a subdued blue and gold-yellow paintjob, but 2007 we did
Highlighter and Rescue Blue and 2006 we did
Midnight Black Flat. I don't know what we'll do this year... either stay with the new colors, or go back to the old. Not much of a chance of black.
-q