Squirrels have fuzzy tails.
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Is there a particular reason why you need it to be thick? Polycarbonate (Lexan) sheets when molded are very strong and wont crack or tear. Hobby grade RC vehicles use lexan as the body material, and they withstand 40+mph crashes.
Another option is fiberglass. I know a lot of people make full scale R2-D2 models from all fiberglass parts and they tell me if you do it right that it can be strong enough to stand on. You just need to create a mold. So if you use wood or another material that is easy to cut and shape then you can create a mold and make parts that way. Just an idea.
My understanding is that when vaccuum forming you can produce any thickness of plastic. The reason its usually so thin is that you try to use the least amount of plastic while keeping a reliable amount of structural integrity. The resultant thickness is likely due to the level of low pressure produced by the vaccuum. so a stronger vaccuum will produce a thinner plastic