EDO,
Heres a German group that cuts their cores with a router. They cut both the top and bottom half side, by side. Then the wirecut each foil at the parting plane, glue them together, and waaahhla, they have a wing.
Actually they go further and vacuum bag these wings in a mold.
http://www.delago.de/ariane/ETechnik.htm
and
http://www.delago.de/ariane/EStyro.htm
Interesting.
Dave