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I've had very good luck building with acrylic.
This building was made with 1/4" acrylic, covered with Precision Products brick sheets.
This boxcar was made from acrylic
I've also made boxcars from styrene, but they're just not as strong as the acrylic. It's lighter as well.
I've had no problems with the brittleness of acrylic. I find it much more rigid then styrene, and it's great for windows.
For cutting openings in other materials (to include styrene) I really like the little Micro-lux scroll saw.
I'll put in another plug for Russ at TAP Plastics. He's got lots of great ideas and is willing to work with you.
This building was made with 1/4" acrylic, covered with Precision Products brick sheets.

This boxcar was made from acrylic

I've also made boxcars from styrene, but they're just not as strong as the acrylic. It's lighter as well.

I've had no problems with the brittleness of acrylic. I find it much more rigid then styrene, and it's great for windows.
For cutting openings in other materials (to include styrene) I really like the little Micro-lux scroll saw.
I'll put in another plug for Russ at TAP Plastics. He's got lots of great ideas and is willing to work with you.