Honeycomb Composites?

[ChuckDickerson]

We have traditionally used ½” SandyPly plywood for our electronics boards available from our local Home Depot. It is cheap enough, non-conductive, easy enough to work with and mount electronics to using simple wood screws, but not exactly as light as I would like. I’m looking for a better alternative this year.

I have heard various comments here on CD lately regarding the use of composites, particularly honeycomb fiberglass/aluminum/plastic panels and particularly for use as lightweight but structurally rigid panels for mounting electronics and such. While I have seen these materials on occasional robots at competition I am mostly unfamiliar with these products. For the benefit of us uninitiated in these honeycomb panel products would some of you please provide more information? Particularly, where do you get it? What sizes/thickness do you use? What are the material properties of what you have used in the past such as weight per square foot per thickness? How easy/difficult is it to work with (how do you cut/drill/machine it)? How expensive is it? How do you mount electronics to it (screws?, tape?)? What else have you found it useful for?