I only ever buy bar stock in delrin for making piston seals for air rifles, find its quite cheap in bar stock, usually buy in 30-35mm dia @ 1000mm length
It sounds like you are over specifying the rail. Acetal, an oil-based engineering plastic, is able to 'do more' than aluminium in certain circumstances. You pay for ability. Plastics are not always cheaper alternatives to metals, something which may people still believe.
The rod, bar is anything other than circular section, that BB buys is extruded, or possibly cast, to size, whereas the panel you want is cut from a sheet 2000x1000x15.
The price per cm3 does not change significantly until you start getting into thicknesses around 60-75mm, where the manufacturing process changes, if I remember correctly.
That is quite a large piece of material, if you think it's expensive try specifying "Peek" in those sizes! Are you making this to existing plans or your own?