My idea is make a 3D sculpt of that piece and make a solid mold to inject urethane foam.
First I started with a low poly version fo my 3D model to make a pepakura cutter project.Because I dont know if is a good idea, I prefer in that piece,avoid the expensive 3D printing process.Is a big piece(a big risk) and the way of made is totally different than the 2011 mags.
When the piece is sticked, I start to add a fine surface of super sculpey and go directly to the oven.
With paint job applied,Ready to make a solid mold with Exaduro compound.
The half piece of mold.
In process of developing the "side B" part.
Making a light volume with plasteline.The red element is the final volume of the injected foam.
Untitled from manu R on Vimeo.
I dont know if that technique work well...so..lets go¡¡
Hey.You can throw a link to Nike pepakura drawings
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