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the Baxter Bomb Squad fell in love last year. With extruded aluminum item. The stuff is great. It's strudy as all get out, lighter than almost anything, and because it has these great little bolt things designed to connect pieces of it you don't have to worry about taking on the nearly impossible task of aluminum welding(thank god).
We used one frame last year that weighed 12 pounds(less than last years parts list book) and we were one of that fastest robots out there. Even at our very high speeds we had multiple collisions and didn't notice any damage to the frame(other than astetics ofcourse).
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College and its wonders. First year and alot of other FIRSTs.
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