Roger, do you guys have a water jet cnc as well that can do very large sheets? I read this technique that some guys used to create molds for HPV shell. They took foam sheets of something like 4'x8'x1" and had the cnc cut out profile templates every one inch of their mold design. They then glued the sheets together and sanded down the edges to make a smooth shell.
I'll find a link for it for you so you can better understand what I am talking about. I want to get a ball park price on how expensive this process would be. (I think the guys that did it said it only cost around $15 a sheet to do, and they maybe 25 sheets....)
http://ecomodder.com/forum/showthrea...ring-1175.html
I've seen another one done like that, but the team had the mold cut with a CNC. Is your company able to do something like that? I am in upstate NY, which is why I am curious.