"cavelamb" wrote in message
...


That was Burt Rutan's particular gift to the state of the art.

A soft foam piece that was easy to develop into complex shapes,
and stayed in the part as a stiffening core.

Or remove the foam completely after layup, if it's not needed.

"Mold-less" construction.

True, but in lies the rub. It's just as much work to build one aircraft, as
the plug for a mold that will build many. Large panels and even two piece
fuse sections save a lot of work, and can produce even lighter panels.