"The reason I asked about making the ribs out of another material is because they don't need the higher strength that the polycarbonate provides. One way to reduce weight would then be to make the top and bottom half of the plane shell as two…"
First, I really like your idea for using RP to manufacture planes. My primary concern with the idea is the surface finish that your wing will have. How much sanding (if any) is involved in finishing these parts?