Antweight Kit

Yes, 4mm walls are definitely overkill. And printing solid walls will also cost you a fortune. Design a space frame chassis (not sure that's the correct terminology, I'm sure some proper engineering types can correct me). As it's charged by the volume of material you use, the less waste material, the more money you can save. Think of how a bike frame is designed, lots of beams to make a solid structure, not just one big lump of material. I'd say the most I've ever spent on a 3d printed chassis is 40 euros, and the least is under 10 euros.

Thanks for the info Duff, i didn't see your comment when i edit my last one.
Do you think 2.5mm outter walls is good just from playing around?
I will do some vents all around the chassis to reduce costs even further.

Chassis A:
http://i1272.photobucket.com/albums/...ps9903836b.png
Volume = 60616.52 cubic millimeters
45€

Chassis B (same but full of holes):
http://i1272.photobucket.com/albums/...pse174a18e.png
Volume = 46062.32 cubic millimeters
52€

About 4000 cubic millimeters less, but he price went up... Anyone knows why? Complexity?

Even at 45€ it's still to much, and that's without the flipper and wheels...

Sounds odd... Have you definitely selected the correct material? It should be white, strong and flexible. Other materials are more expensive.

Yes, i have selected the right material....

I even made this alternative version with no round parts:
http://i1272.photobucket.com/albums/...psbb016488.png

Printscreen of my shapeways models:
http://i1272.photobucket.com/albums/...ps0c014f95.png

Chassis2.2.3.2 - Volume = 60616.52 cubic millimeters
Chassis2.2.3.2current - Volume = 44754.50 cubic millimeters
Chassis2.2.3.2-test - Volume = 40133.38 cubic millimeters

It lost 2/6th from the 2.2.3.2 version to the test version, but the price is almost the same, this is very confusing... I better wait for Friday, when i will have my 3d printing workshop.

I know they give you a discount if your model is of a certain density, so I think its something to do with that.

From their website: We also offer a volume and density discount on Strong & Flexible materials. For models that are greater than 10% dense (material volume divided by bounding box volume), after the first 20cm3, the remaining volume is calculated with a 50% discount.

So it looks like your model is right on the boundaries of density.

Thanks once again for the info Duff!

I will wait for my workshop to learn more about 3d printing with professionals and know prices here.

3d printing still is expensive for what i had in mind... I will do some designs where the body is made out of carbon fiber sheet, it's very cheap on HobbyKing.

You could try getting some kit's laser cut. More assembly and design required but should be cheaper as you might be able to squeeze many robots on one sheet of material and set up costs should be less.

Also my servos were fine aside from some drift on the neutral position due to some flexible glue.

That's what i was thinking about Jordan, some laser cutted CF panels. They have a 135watts laser cutter on the lab.

I am changing my 3d printed design to be even smaller. It was a rectangle, so the front had many unnecessary space. For now it's with 2.5mm walls, and the battery/servo mount and wheel cover with 2mm. Should i keep the 2,5mm walls or make it all 2mm thick?

I don't know what algorithm Shapeways use, but I've found that some online, automated 3D printing price calculators will give you a different price depending upon the orientation of the part (it's generally to do with the z height of the print, as that's what takes the time and therefore dictates the cost).

I noticed your models are arranged such they are almost as tall as possible - maybe try lying them down flat.