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Re: Sheet metal vs Tubing Chassis
As all have said above, it's a matter of what works best for you. We've never used tubing for the chassis, and only used sheet metal as part of a kit chassis. Our second and third robots were made of extrusion (6063, I believe), a combination of c-channel and angle with a bit of bar and plate here and there.
Don't let your new sponsor's first custom part be your chassis! Design some smaller parts like custom mounting brackets for them to fabricate first, so you can verify that the flanges and holes end up where you expected them.
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