I'm shocked that the dude could get such a uniform shape!!
The initial layout reminds me of my early years on a drafting board, man I disliked those projections. I suppose any modern 3D modeling program solves those issues, as long as you can print full sized drawings. (I recently bought an ancient HP DesignJet for just that purpose)
Thinking about the layout and those relief cuts, I don't know if my 3D modeling can develop them. A flat pattern layout might need to be made first, then hand calculated relief cuts based on the variations in stem to stem distance at multiple waterlines...hmmmm, gotta think about that a bit.
Not sure how the Divinycell would like being contorted like that. When I was gathering stuff to send to you, I accidentally snapped a piece that I flexed too far.
Strategically placed heat could certainly help the foam to submit to your will, but I'm thinking female forms, and narrower pieces of foam would be more reliable.
Pretty sure you're gonna be lead on this, I'm expecting to be homeless soon and all the fun will be on hold for a while.