barkster -
here are a few sites you might take a look at. I assume you are talking of molding in fiberglass/carbon and resin? You could build the mold (a 2 piece female mold) on the cnc then layup the two fuselage halves in the mold and when cured, release and join them together like the old plastic model days. I'd use delrin/acetal as the mold material and a bit of pva release wax.
Else the sites have some good ideas too: https://www.cstsales.com/How_to_Articles/fiberg0.htm http://www.rcglider.com/GOV.htm http://www.inlandsloperebels.com/tips/tips.htm http://www.favonius.com/soaring/lost_foam/lost_foam.htm
The lost foam approach is kina cool. You could make the foam fuse then do the procedure. OOps another secret outa the bag! Gues I won't be selling any of those now.....  Jim
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