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?

Even if you get the foam profiled on a CNC (not cheap) you will still have to seal the surface and add some sort of reinforcement before you can take a mould from it. So there will still be a lot of hand finishing to do. I think you will be surprised how accurate you can the shape by hand. It should be possible to match the left/right profiles to within a millimeter or so.