At the moment the materials are defined as CRFP just for looks, but there are some rules I'll have to revisit on what can be carbon fiber as opposed to glass. S-glass still gives a fairly rigid structure between typical E-glass and carbon. It looks complex but if I use one-off molds with dissolvable foam, it shouldn't be too bad.
Alternatively what might be the best bet would be to direct rapid prototype those complex curvature duct pieces. SLA gets a bit expensive, but 3d-printing out of black ABS is relatively cheap. The machine we had at school was something like $5 per cubic inch of material, and there's not an awful lot of material there.
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