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Old 01-24-2017, 10:02 PM   #52 (permalink)
freebeard
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No doubt they do some internal, proprietary testing.



Here is what I would use; it goes by commercial names like Polymetal and Alumapanel. It is a 3-6mm core of recycled thermoplastic with a .007-.014" aluminum skin on one or both sides. It is used, for example, in commercial signage.

The material I experimented with can be sheared, rolled, and braked by hand and is about as stiff as 5/8" plywood at 10% the weight. I propose a 45° roll followed by a braked edge, butted together to make a radiused edge. The seam across the radius is held by a flexible H-molding.
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