Please reach out to your Wing and Region DofE Officer if necessary, they can help with expeditions. Lots of Sqns don’t have their own AT staff for Expeds but work with other Sqns who do or join Wing run Expeds.
If you have Cadets who want to do DofE please don’t let not having AT staff stop you. There are lots of options available for the exped section
You make it sound like ‘they’ are being difficult. The requirement for a NGB awarded outdoor qual for things like DofE expeditions really isn’t a them and us problem.
Just look at even recent news with the scouts. Then look back and less recent stuff like the Mourne Mountains incident.
The general requirements around AT are pretty well balanced in terms of safety need vs access, IMO.
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I have a P1S+AMS and I’ve just ordered an A1 Mini combo so that I have a printer that I can take to the sqn. I’ve logged 800 hours since July and it’s been such a workhorse. Have used it for multiple projects, both inside and outside of sqn
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Love it!
I’m currently trying to teach myself to use Blendr. So many hours spent browsing Thingiverse etc.
When you’re a hammer, everything looks like a nail!
You mention the wind tunnel, at RIAT 2023 Moog apprentices demonstrated one they made. Might be worth getting the cadets to approach the apprentice supervisor directly to link with apprentices for an oven ready project https://www.moog.co.uk/
The guy doing the demo said one challenge was cutting and gluing thousands of plastic drinking straws at the intake end. Interestingly, this detail is key to creating laminar airflow. Sorry no photographs 
Another thing you could make - flight progress strip holders
Existing design on thingiverse Flight Strip Holder by evenar - Thingiverse
Use pre-printed blanks, or maybe a receipt printer. Find receipt paper to match the height of the holders or adapt the holders.
Add to basic ply and dowel/broom handle frame and play ATC with flight simulator
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