Suggestions for new design Aluminum Mopar SB clean slate (kind of) cylinder heads
Interestingly enough, one could actually custom build (it's not that hard, I've built desktop units from scratch) a 3d printer large enough to print a cylinder head. Then, using PLA and the minimum amount of infill required to keep the shape, use "lost pla" casting.
Either have someone take a mold of a really good set of ports, or model completely new ones, then base the overall design on the ports.
With lost PLA, the end result is very similar to lost foam in that the PLA is basically vaporized. All said and done, I'm unsure of how practical casting a large item using PLA and hoping it all burns away is. Something that large might simply be too large, HOWEVER, doing a section of a head, as in one cyl worth, might very well be possible and allow for flow testing as well as preliminary evaluation of a design in the physical space.