[Billfred]

One piece of advice: if you can get vectorized logos from your sponsors, do that. It'll save a step for many graphics people, and generally yield nicer results. (Designing our shirt this year was a cakewalk.)

Last year, I printed off our side panels on a plotter here at school. The whole robot ran about $17, though your mileage may vary. You'd want to protect that, though--lamination alone helped a fair bit, but it still got pretty banged up over the season. Get some thin lexan if you go this route.