From 24,000 suppliers, Boeing awarded Foam Matrix, a
small California company that got its start in surfboards, its Supplier Innovation Award for 2002. The company has 12 employees and reflects the military's push for "outside the box" thinking. The technology, used to build wings for unmanned aircraft, starts with liquid foam being poured into a large molding block with all the electrical wiring and other components. When the foam core hardens, "composite fibers" are applied and the wing is returned to the mold to cure.

http://www.avweb.com

>...starts with liquid foam being poured into a large molding block with all the electrical wiring and other components. <

I hope that does not give someone the idea to use this technique for manned planes .....

hank@ster