Printed out unfolded 3D file and cut up and stuck it together with tape. Scale was 1/8th and it worked really well and the resulting model looks good and was easy to put together. At full scale the velomobile shell will only require 2-3 sheets of coroplast / coreflute, the estimated weight of the shell would be about 2.5kg, so if the rolling chassis weighs less than 17.5kg I will have a velomobile that weighs less than 20kg . The next step is to make a 1/4 scale using 2mm coroplast / coreflute and maybe tweak the design from there. The beauty of this design is that it is totally scalable and able to be customised to individual needs / size / dimensions as required.
After a bit of playing around finally got the model to unfold to flat the way I wanted it to. Just have to print to a 1/5th scale and fold it all up to see if it works. The model below is not symmetrical that is because I wanted to try a different nose style for each side.