Hey Brook, sorry didn’t see this. I’ve seen some pretty decent sized parts (roughly the size of a backpack) done but they were done on big, high dollar machines too! For smaller scale beds and projects, you will likely need to do modular tools or parts, like my Spitfire build http://www.3dlabprint.com Only you would need to develop negative molds. I used the TC-300 2.5lb rigid foam for my wing: http://bjbenterprises.com/index.php/tc-300-a-b/
@Troy_Peterson I took a closer look at the Spitfire from http://3dlabprint.com. I think I need to grab a copy of that design and print it. Did you complete your build? How are you finding it?
I just finished it and starting to add RC gear (motor, esc, servos, etc). It’s a challenging build but gives you a good idea of possibilities for flyable 3D printed parts. Try printing a sample file from Thingiverse.
Did you see on 3dprintlabs the 3D long image? It says first manned printed plane???