I’m confused by the statement and some posts emphasizing one sheet only. I assumed it meant you cannot use sheets bigger than 12x24 for any single fabrication. But is that the case, or are you really limited to one (1) 12x24 sheet per Robot?
This would seem strange to me considering you are not limited to quantities for other VEX structural materials.
We are a rookie team who competed in FLL last year as rookies also.
Thanks,
Jamie
Coach/Mentor for Teams 5275A&B
The Valley School, Flint, MI
Not an official answer, but I am 99% sure that it is the literal 12x24 piece of polycarbonate. As in if you add up all the pieces of polycarbonate from your robot you could “puzzle piece” them back into the original 12x24 piece. Additionally if you use a thinner piece of polycarbonate, you aren’t entitled to more polycarbonate as if you had cut the polycarbonate along its thickness. The limiting factor is surface area, not volume, if that makes sense.
^ Fixed that for you
It is only 1 sheet of 12x24 and I believe it has to be no thicker than 1/16th of an inch.
that is correct
you may only use one sheet
trust me, i would know from last year 
It is important to know that you can not simply add up the areas of seperate pieces that you use to equal 12×24. The pieces must be as if you cut them out of a single 12×24 in piece.
And the great thing is that McMaster-Carr actually sells them in 12" x 24" sheets already - McMaster-Carr
Thats what I meant by puzzle piece it back to the original piece, but thanks for clarifying.
I believe the reason you are limited to the amount of polycarb is so that teams don’t try to make their entire robot out of it… The people who made the rules want to offer advanced teams the chance to build with polycarbonate, while still keeping the competition fair to teams who don’t have the budget or experience to use it.
Also, greetings from Team 7581H in East Lansing! Our teams also sprouted from an FLL program. Will we be seeing you guys at the Pontiac tournament?
Thanks for the welcome Raptors. We are signed up for the Romeo Autodesk Tournement right now, but depending on how things go over the next few weeks, I may sign us up for something sooner.
You’re welcome! We’re not planning to go to the Romeo tournament, but I hope your team comes to some more tournaments! Competing in multiple tournaments gives your team a chance to work out bugs with the robot that are only seen under the conditions of competition. Our rookie year we went to 4 tournaments, and it paid off! By the end of the season, we had a tournament-winning robot, and it was a great learning experience to improve it after each competition.
Here is the official answer from Karthik concerning the same question.
https://vexforum.com/t/answered-question-on-rule-r7f-use-of-non-shattering-plastic/22122/1