I need to make a rubber foam mannequin?

Basically my wife and I have a business idea and we desperately need help. As we have young children and I struggle making good money our budget is pretty limited.
Without giving away our whole business idea we need to produce life size Polyurethane Foam rubber figures of humans. We need them to be flexible but firm. The only way we can do this is by using a Mold. We can get our hands on the material required but we are really stuck on how to make a mold. My wife can sculpt but to start we want to use an existing mannequin we already have and try to replicate that except in rubber foam.
Please can anyone tell us how to make a mold from the mannequin and what materials we will need.
Anny help at all would be great.
ps what materials would i need and how would the foam be injected and cured?
Hi there the first answer didnt help at all. I didnt want a low down on love dolls haha i want to know about the process how to make foam rubbr dolls.

Your idea already exists.
They are called various names, and are most often sold as adult companion dolls.
"Real Doll," "Dream Doll," and others. Some have movable mouths and eyes, and newer models even have robotics, so that they can converse.
They cost (retail) about $7,500 and up.

There are also "art dolls," but they have a very limited market.

http://www.softsculpturedolls.com/home.html

It is not an industry someone with a "pretty limited" budget can easily get into, as your startup costs for a quality product will be quite high. These are most often produced overseas in Asia, to custom order (hair, eye color, facial features, etc.), so you will have difficulty in beating their prices, not to mention finding a market.

If you are truly talking flexible mannequins, they too, already exist, and cost about $600.

http://www.mannequinland.com/flexiblemannequin.htm

Research your business ideas on the Web before you invest in them. You will find that many already exist in some form, and only if you can come up with a better or less expensive production, is there any money to be made.

Best of success to you!
~Moz

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