Why can't front panels be aluminium?

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Thats the beauty of 12mm Tufnol, get your router out: job done.

Go for the paper version not cloth, it's actually stiffer as well as cheaper.
The guys at Tufnol.com are very helpful.

I got two 12mm baffles for my Olson Ariels cut for £56 GBP inc tax and delivery from a metal merchant.
 
What I like about the laminate concept is the possibility of making a thin (no backside driver reflections off the rim), very stiff and extremely damped (in fact the layer facing the world doesn't have to touch the driver or anything but the adjacent damping layer) for little cost and minimal machining. Then again, I'm also considering it for a 4" Jordan, not a 12" NHT. Though I have one of those laying around too. :)
 
Aluminium is expensive and hard to cut pure and simple.

Its looks terrible unless its polished and is very heavy in thick plates of 10 mm and up.

You should try and price up the cost of an aluminium baffle or enclosure and then tell me what you think, is the cost justified in the end? who knows :)
 
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