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I don't really know if there is a substitute for styrene, other than wood, cardstock, or possibly foamcore, which you have ruled out. Maybe what you need is a different source fo styrene. The model shops are probably the most expensive way to get styrene. Other ways might be cheaper, but require more "leg work". Try sign makers for off-cuts or other excess materials. Companies that supply plastics might have suitable materials in bulk at less cost than the LHS. Let us know what you find out. Andrew
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