I have carved them out of both cedar and balsawood. Used a regular old plunge router. I would mark the depth contours onto the blank based on NACA foil generator program results. I would divide it up into six to ten steps and the result would look like a topographic map. After routing as close as possible to the lines, I sprayed flat black paint on the blade. Then, used a rotary sander with 40 grit discs to rough shape the foil - using the black paint as a guide. Finally, did the finish shaping with 80 gtit flat sanding block. You can actually get pretty acurate results this way. Does the shopbot carve the finished contour or do you still have to finish the shaping by hand?

And also, recommend whatever you laminate to the outsid of it, include a layer of 5 oz. Kevlar underneath it. This adds a tremendous amount of damage resistance.

Kevin