Poly carb I think would be the best. Nylon may work, but I could see UV breakdown over time. ASA I would put below poly. TPU may be 3rd after poly and asa. PETG would be like 6th. I'm more resin kinda of guy, but I wouldn't use that outside, it certainly would yellow at best over time and wouldn't give over weather fluctuations over time either). But I use it more for figures/toys etc.
Ah! I didn't know they had polycarb filament. I'll have to look into that.
Yeah, I could see resin yellowing pretty fast. I suppose if one were so inclined to use 3D printing as part of the workflow, or at least conceptually (for a durable piece)... They could use a 3D model to create a plaster mold along with fiberglass / epoxy to build up some thickness, then sand / prime / paint. Of course there's still the issue of printing a 5ft or 6ft wide model on (presumably) a printer that has a 10" x 10" build plate. Good luck getting those parts printed without warping, let alone the assembly (ugly seams).
I don't know if thermoforming over a 3D model would work (depending on the required oven temp, like in one of the pulled plastic face ovens), but it should work fine with an open frame vacuum former.
In any case, I think the OP would be hard pressed to find a faster / more cost-effective solution than a CNC outsource.
