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Re: Plexiglass
Whether you use acrylic (Plexiglass) or polycarbonate (Lexan) I would suggest that when drilling holes in it that you re-grind your drill bits to make them "pointier" than a typical jobbers drill (about 60 degrees sounds right). Alternatively you can purchase specially ground drill bits for plastics. Yes, you can drill the plastics with a standard bit, but the pointier bits cut nicer and reduce the likelihood of cracking in plexiglass.
We use lexan extensively on our robots and have found it formable and durable. Plexiglass tends to be subject to cracking if you don't baby it carefully, while you can bend and fold lexan just like you can sheet metal.
We have also used a plywood, and recommend baltic birch, but... of course... you can't see through it.
Jason
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