There are heat seal type machines that literally weld the plastic together. Stitching can be used with the appropriate UV resistant thread and reinforcing materials as needed. Best bet is to consult a professional tarp and trim business. The sewing machines suitable for this type work are your good old sail making ones, although the main limiting factor is the throat of the sewing machine restricting how much material you can put through so domestic machines will be o.k. to a point..
I would look at any existing bimini's and see what has worked for them. Making them too light will only let them fail early.
Good luck.
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