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My friend just picked up a bunch of alumalite. It is like coroplast, but thicker, and with .019" aluminum bonded to both sides. We thought we could bend a curve in it over a barrel... this stuff is STIFF! The two of us could not for the life of us put a bend in the alumalite, and that was going the weak way! We are going to try using a sheet metal press to make bends and a skill saw to do the cutting.
He also got a single sheet of polyvynal. this is more of a foam core with thinner aluminum bonded to both surfaces. This was much easier to bend, but still much too hard to get a 10 inch radius out of it.
I would say either of these materials would be much more ideal for building a semi permanent/permanent aeromod, where the coroplast is fine for small spans, but bends easily and requires support.
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