Thanks for taking that extra step. I bookmarked you post. I understand that varying parameters, more than just ground clearance (straight vs exponential horn, etc.) could optimize the result. And that it's for comparison purposes only. I'll take 10% as the significant number. It's not really my idea, it came from a rectangular duct under a drift racer or something.
I mapped out how I would tackle coroplast FWIW. I'm a fan of formless construction. If you make a wide slot in the flutes and backside it would result in a radius. The ones going laterally are the problem, so you lay out with diamonds. Chain them together and the result is a long strip with non-parallel edges.
That first body you built could be rendered as a triangulated low-poly model. I don't know much about the tool path from the Solidworks model to a cutting pattern.
If your thinking fibreglass/carbonfibre bodywork, look into
http://basalt.guru. It's a competitive product. You could for instance layer a fiberglass skin with a basalt mesh reinforcing backing, the thermal expansion is the same.