Klavs has posted an interesting cutaway image that shows how he designs his 3D models to be ultra cost efficient when 3D printed at Terran Fleet Supply. He makes no money off all of the fabulous ships he's produced, but he constantly works to optimize his fleet so that more fans can affordably share in the fun. His faithfully recreated Hellcat is just one of about twenty Wing Commander-inspired fighters that he's added to his collection. And that's just counting the modern designs that have come online since detailed color textures became feasible last year! It'll be very interesting to see how this technology continues to mature in the near future.
Well the models are pretty hollow as is. Obzoiv! The wings are also a bit hollow, but there still has to be some structure in there to keep the thing from being wimpy.
And the goal is, eventually, to get ALL the ships out there Klavsified and ready for printing. It's just gonna take me a while. Stay tuned!