He actually might be a better source to get what you are looking. The only experience I have with using plastics is mainly vacuum forming. I would create the form you want out of 'yellow' foam and that figure out the plastic that would work best given the shape and properties of the form. And then you would have to find a vacuum foam machine. I dont think this would be the best way. I would actually suggest the carbon route and you could always finish it how you like. Laying carbon on a foam you created out of something, yellow foam would work, and then applying the epoxy how every that is done might work better. There is much more control doing it this way.
I know the guy that helped design and create rolls rolls.
www.rollsrolls.com And I can try to get in touch with him and ask some questions for you if you have any.
Take a look, I am sure they would enjoy the extra traffic.
