Re: I think one danger is the canard stress
Most of these CAD/CAM Programs like Soildworks/Inventor/etc., have all the different modules built in today, or you can add them. Alibre, was like $100-$150, I think they renamed it Geomagic, said it does every thing Solidworks can do.
The 2 part epoxy Plastic is very light weight, like the Blue Foam, but much Stronger, floats, gas does not affect it, you can cast in hard points. You can sand, machine, drill, paint, it. It can also be dyed different colors.