We take 1/32" polycarbonate and spray paint the inside orange. Then we print up stickers and stick them on the outside. Because the paint is on the inside it doesn't scratch, and looks shiny. Its easier and cheaper than powder coating, and the plastic helps protect the robots electronics - so its functional too.
We started making this "armor" in 2006, and it looked really good so we took it a step further in 2007 by covering the whole
robot with it.
Painting eyes and fangs on your robot also helps
