2) For the shape. I'm thinking about making a male in wood, lay the fabric on top and once is cure machining the contour. Is this a good idea?

If you made a small length of carbon channel as suggested you would then just mark out the profile you want and typically it would often be cut with a diamond grit disc on an angle grinder or die grinder. Then shape further with sanding disc on an angle grinder. You could even cut the basic profile shape with a metal hacksaw blade and then shape further with the sanding disc?