Are you concerned about the profile/shape being identical? or the surface finish? 

Thanks all.

Interesting point of view Warren. Do you think it's possible to match both sides? When it's painted any kind of flaw would surely be highly visible?

CAD and Lazer Cutting seems a little OTT. Hand cutting/shaping should be more than adequate. Trust your eye. 

Cardboard then CAD I would say.

I want to design something similar to the below (not to copy it), but I'm unsure of how to go about it.  I'm thinking the high density foam to get the shape of one side and the front, glass it, flat it etc etc before moulding but what about the other side? By hand it's not going to be identical, so what about someone with a digitizing arm to map it then "flip" it, then have it lazer cut in foam? 

Or make up a cardboard mock-up and find someone who can CAD it before lazer cutting foam etc?  Any ideas anyone?  How is this stuff usually done?