[WB-avl]

How about an RV with no fiberglass parts?

Check out this Ford sheet metal rapid prototyping machine.

It looks like it has a lot of potential for low volume production, etc.

http://gizmodo.com/fords-new-prototyping-machine-turns-sheet-metal-into-c-659217381

 

[aeroaddict]

That is amazing. It looks like a 3D english wheel machine.

But at the cost to capitalize I doubt small companies such as Van's could afford the equipment.

 

[WB-avl]

It does look like a very expensive machine.

Maybe at some point you will just be able to send them a 3d cad file and they ship you back the part?

 

[LAMPSguy]

Stick with fiberglass

It might be just as easy to stick with fiberglass/CF and have a rapid prototyped build out of that. It would be great to have a 3D scanner at the local chapter, scan your wing tip, then Van's sends you a custom tip, etc that pits perfectly with no trimming!