I just saw your reply. I actually know quite a bit about his process. I worked with him on my master’s project a few years ago. He is a pretty awesome and interesting guy. He way very helpful in critiquing my work and providing guidance.
He finds his inspiration in a lot of natural objects. Take the surface of a rock for example. He looks at the way various surfaces flow into one another. other things are how trees, bones, fruits, etc flow.
He prototypes a lot of his pieces using a 5 axis cnc router. he uses a foam base that is then hand laid with fiberglass and finished with standard automotive paints. A lot of times he will have to use a few pieces of foam that are glued together in order to get such complex forms.
I know he uses Rhino with the T-Splines plugin for his software. I would need to check some of my old notes, but he may use cinema 4d also.
If you want, check out my portfolio on coroflot and look under the project (b)ONE. It shows some of my process work using his methods.