I use Sintra for all my robots lately. Very easy to work with (drills
easily, cuts best with a router) and no static problems. It is both
strong and light. Sintra also paints quite easily. It can also be formed
using a heat gun, and cemented with pvc cement available from any
hardware store. 1/4" Sintra is widely available and cheap.
On largish robots you may find that Sintra, like most plastics, may sag
under the weight of batteries or other heavy items, in which case you
will either need to use a very thick piece (which can be expensive) or
reinforce it with plywood or aluminum framing. For smaller robots, you
should not see a problem. Definitely one of my favorite materials.
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There are a lot of nice things about it as indicated by the
But, because of the expanded foam core, it's not really rugged and it
doesn't work too well if you want to secure fasteners directly into the
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