[joeweber]

The 2004 and 2005 season we used HDPE. Pictures @ http://team1322.org/pictures.htm It can be heavey but it has alot of give. This was befor bumpers, other robots would just bounce off with out damage. We found a local place that would weld the plastic together.Our robot was completly plastic except the arm. The plastic was very easy and safe to work with, students could cut it and not get shavings in there skin or cut themselves on the edges. You could use a jig saw, router, hand saw, and drills with ease. We still use HDPE (High Density Poly Etholean?) as mounts for motors or structure supports between aluminum frames. This seasons robot we used two blocks 2.5 x 5 x 6 in. and cut it into a fun looking "Y" to get around some items so we could mount the motors in a particular spot. The stuff is strong and easy to work with. Also you can use it as a low speed axel support or make pillow block out of it. Look close at this picture @ http://team1322.org/DSC00703.JPG you can see the motor mounted to it.