I can pick up a stack of 5 4x8 sheets of 1/8 coro in 1 hand. I don't personally think that I am the Hulk in real life but maybe I should go tell the news about my incredible feats of strength. You can always hang them off your bucket on a simple hook unless you and your tools are hitting the weight limit and can't take another 10-15 pounds. You are also not hauling up the whole sheet but probably 40-50% of one.
Making simple interlocking tiles of any size on a CNC router should be a non-job for a real CNC programmer with sign shop experience. You only need to level and or measure out one and rest will lock in and all you do is move your bucket around clicking them into place. Can always cut in slight tolerances for the interlocks. Since coroplast is fluted, your flute direction for patterns can make it conform to the surface. 30-40' sign is about 4-5 sheets of coroplast if your letters are over 3 ft tall and need pins if not then you might fit 2-3 8' foot lengths worth of patterns onto 1 sheet.
Push through pattern style takes even less since you technically only need the tops or bottoms for alignment and you can level the pattern or turn it any direction with 0 sag unlike paper or banner or tyvek patterns.
You need access to a place that will cut these for you though. It will never be profitable if you have to pay for it as it's some sort of a special snowflake CNC job.
Former owner of the shop I worked for actually re-used his paper patterns on different jobs. Stored them all in a shipping container in the back parking lot of the building like some sort of a hoarder. Thought he was saving hella money doing it this weird scrappy way but he lost dollars chasing pennies every time.
I am not out to judge the way you do things, I am sure your way of doing it is profitable for you. This is just my personal working experience and how I pushed the limits of how many installs I can do a day.
One of the more extreme examples was hitting all the hospitals in metropolis the same day to change over all their Emergency room area informational vinyl. We achieved that by having the secretary drive me around to avoid me having to find parking and she picked me right back up and we were en-route to the next one.
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