@PaulK
Don't know about the wings, but for formers and molds in general, I've had the same problem when trying to design my own mini swappable aircraft (especially due to the larger relative thickness of the foam to the characteristic size of the planes). If I tune the tolerance so the planes build perfectly with a lasercut kit, the molds don't wrap all the way around when my friends handcut the same plans (properly), since the laser slightly melts the edges and makes the formers slightly smaller than the plans say they are.
To alleviate this issue, what I do is design the molds to be slightly larger than necessary, so that regardless of which way you cut them out, you custom trim the piece down to meet mated when wrapped around the formers. That might be very difficult for a master series plane though due to the size of the pieces. I don't know if FT can create an all-in-one solution to this, like maybe offsetting lines carefully in their laser files to match a typical handcutter's stroke.
@Splinter189
