Laser Cutting

[PJ-27]

I decided to make up some intricate designs for my BW with the intention of getting the pieces cut on a Laser Cutter.
Being a BW I chose Polycarbonate, since it's strong, light and means I can cut each of the pieces in 2D but have the sheet thick enough to assemble a 3D robot afterwards.
Plus polycarb is cheap, readily available and see-through!

Anyway, it didn't work. The cutter, although powerful enough to do the job, just melted and yellowed the polycarb. Is it possible I'm having issues because it's the Excell D kind?
I phoned round a few local laser cutting companies and none of them will touch polycarbonate - bad smell, finish and mess being their complaints.

One of the companies is still happy to do the work but have asked me to pick a different material, so my question to the forum is what should I pick?
Does anyone know how Nylon or HDPE cuts? Any other suggestions?

[Max]

I know this thread is a bit old but I wondered if you could use polypropylene as armour on a beatle weight as it is supposed to be tough and flexible so it soukds like hdpe. I am not sure if it is an option for laser cutting?

[daliad100]

Recently took apart a pressure washer made from polypropylene, took several smashes into a brick wall to break after sawing all the way around the seam didn't open the case.

I then applied hammer thinking this might be some good robot armour like yourself you but ended up punching out quite neat circles of plastic. Might be reasonable armour in thicker pieces but it's still quite brittle so it may not hold up to some of the weaponry.

[PJ-27]

Polypropylene is a bit like a poor mans Polycarb, I found similar issues with laser cutting though.