There are a few ways you could do it.. You can essentially build it like gehry would a real building, make your curvy steel structure out of flat pieces of chipboard or balsa, make a 3-d grid, and cover it with flat "shingle" type pieces. It won't be totally smooth, but should get the form across, but will be a pain in the ass..

you could cast some sort of resin or plaster..

you could make an armature and cover it with wire or some sort of mesh..

really none of these are probably a perfect representation. You might want to do a combination, by doing a small casting of the overall form showing what the building would look like overall without much detail, and then a larger scale detail section showing how it might be constructed more realistically give more material definition but without building the whole thing..

just some ideas.

This wasn't a super crazy form, but it did have a somewhat compound curve that I made the model in the first method I described..





again, not perfect, but it might give you some ideas..

carve it or make a foam piece using 3d milling, then vaccum forming
ir you use high density foam, you could keep shaping it to make it smooth..
one could also use modeling clay the way industrial designers do

3d honey-comb!

sorry, it's late at night and i could not resist the tentation.

hahhaha

if you have it as a 3D model already, you could give Lamina a try. I've never used it myself, but it seems as if it would be an appropriate tool.

ive been planning on using a structureal frming with some sort of metal wire and panty hoes. that would work

pixelwhore, do you know of anyone using Lamina? I have read through and it seems like it does what it says. I am very interested. Might buy an edu copy for the university to try out . . . guess I'd like to know if anyone has tried it.

Gehry actually uses carpet and a glue gun for working out the folds. There was a presentation on the model making for the Disney Concert Hall at the MOCA a little over a year ago. Quick and completely malleable.

try
http://www.mutr.co.uk/prodDetail.aspx?prodID=577

or even better:
http://www.mutr.co.uk/prodDetail.aspx?prodID=576

i'm sure you can find them in the states as well

bake plexi-glass and form it when its malleable, or use an electrician's heating gun for better accuracy. I think some of the older Ghery models I saw in a book were noted as being made from a heavy felt covered in some type of wax

...seen a lot of this around the first year studios at the GSAP.
You can heated, scored in the laser cutter...ect.
Possibly your best bet.

i said it before, and (etc)

don't use raw onions

you turn into an octopus after midnight?

now i'm curious.
do werewolves wear glass slippers?