Cheers folks, yes the render mode is rather fun. This is about as good looking as it will ever get. Downhill from here!

Just using normal PLA. If I get strength issues with PLA I will probably buy in printed ABS. Nylon would be cool also but I hear it has terrible adhesion to epoxy, so wouldn't be much good for the armour panels. PLA+ sounds good as long as it doesnt lead to loads of parameter optimisation again to get it printing!! The terms also need some research I think. Terms like "stronger" and "tougher" all have different meanings in an engineering context so would need to get to the bottom of which is best for this application.

Yeah I am inclined to agree about the battery, would suck for it to be on the weight limit and struggling to complete fights.

Just getting on to the electronics now which has been a frustrating experience. One of the fundamental requirements for a soldering iron is the ability to melt little bits of tin, which is something my own one fails miserably at... Going to start using a gas one as the one Paul had at Botfest looked the business!

First video on the build here: