Since we already proved that you can heat bend foam and it will stay that way ….. you could pre-bend sections of foam on a “form” and then just glue them together , then cover … We’ve been pushing around that idea for a while …
“ I think skin on lashed frame maybe with a double fabric wall with foam injected between might be possible, Could be super light and strong.
“ …. yes it “should”, but injected foam doesn’t always expand the way you want it to ...
Maybe between two forms to keep a specific shape ??? That would be super eh ??? Finished panels …
Yes the Foamstream is just a half cylinder sitting on a wall with a rounded nose (the only real compound curve part ) … And Yes, we did have access to a CNC router , and we’d do it all over again if we had to … It worked so far ( 6 years now )
Now then , taking a note from the Tipi, Fabric stretched over a frame ( sounds like a Tent eh ? ) and with an inner liner to allow an air space in between ( insulation) , that idea could be applied to a trailer built “similarly” to an aircraft fuselage ( formers and stringers ) with an inner and outer skin … You could make the frame any shape you wanted that way … or even an EGG
The problem is most of these methods would require a lot of labor … even just cutting saplings and bending them to shape as a frame would take a good bit of effort to get "just right" …
Ther Old Timers steam bent Hickory or Ash to make Bows for their wagons … same process could be used for formers … Lots of possibilities … Could be Fun !!!