[EricH]

Originally Posted by XXShadowXX

I'm not sure what it's called but there is a plastic material that is in a cardboard like arrangement (two sheets with vertical supports in between). My team used this last year to save wight it weights 1/5th as much as lexane (used before). That should save some weight. (6 pounds roughly) Then you need to trim about 2 pounds...

Corrugated plastic/matroplast. It's used in signs a lot. It's tough enough to support a robot's full weight over a 36" square, supported only on the sides. That's 1/4" thick stuff, IIRC, for that purpose. There might have been some 1/8" plastic on the ramps leading to that...

It's almost as strong as Lexan, but doesn't have quite the puncture resistance. On the plus side, you can get it in one of your team colors.