Greg if you drop below 50 inch span for electric it might be worth trying/specifying 3mm foam board or just strip the paper from the inside by damping it??
This is an option. I will have to do some R&D and try some different methods to see what works, what doesn't, what is simpler, what is a hassle, etc. I would opt for FFF for electric versions of any of the ducks between 30"-82" if the finish of the exterior is not of the utmost importance.
Another option is Depron (
or other variations of it by other trade names) for wingspans under 40"-45"
(I would need to do some stress tests to see the maximum wingspan that can be handled by Depron, but ~40" sounds feasible).