How are bellypans made?

[MrForbes]

Originally Posted by DELurker

Unfortunately, our Lexan was a little too gummy to use the tried-and-true method of score it and snap it at the line.

If you can score and snap it, it's not polycarbonate! It's most likely acrylic (Plexiglass).

I'm not too keen on starting with a material that needs a lot of cutting to make it do the job, for any part of the robot. But I guess if you have access to machinery that can do this, and you like drawing neat designs in CAD, then it kind of makes sense. We usually do fine with a sheet of plywood, of a suitable thickness for what's attaching to it and how big of an area it spans.