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Coroplast can be bent. You can score it with a razor blade and make bends. But there really is no easy way to make round features.
I've been carving pink polystyrene insulation foam to make single-use molds for fiberglass + epoxy resin. Polyester resin eats styrofoam. Fiberglass works great for me. It should be possible to make professional-looking parts with it, but I've mostly stopped short of doing that. You can get a smooth finish and paint it with automotive paint, but mine is somewhat wavy.
I haven't used foam core board, but I'm sure it would be easy to lay up a sheet of fiberglass over it to make a more durable part that holds its shape well.
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