I can report I just tried this on a piece of 1/4 smoke Lexan. Per a tip I recieved from a relative in the plastics biz, I used a router and a straight bit and it worked pretty good. Just take off the fences on your router table and go. I followed just outside the tracing line and sanded the edges to the final shape. I made ONE wing ( learning curve - I trashed the first piece ) and I'm going to use it as a template for a set made out of clear MR Lexan. MR is Marr Resistant and it's what they use for race car windows. I've been experimenting with polishing the edges on a buffer, but they might look best with final sanding in the 400 range or so instead.