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Dont mean to be blunt, but you obviously have no idea how much the tooling for something like that would cost.
The tooling required for a one off frame mould at this level of quality would probably be more than their entire anual sponsorship budget for the team. A lot more.
You would be suprised at how little money big companies like this are willing to throw at custom projects for anyone other than the likes of Sagan, and even he only gets the sort of level of custom shit he does, as Specialized make a crap load of money out of floggong Sagan replica bikes to the masses of his fans.
Yes, they would make him an entirely custom frame, by hand if required. Moulds are expensive to make, but not difficult when its part of your bread and butter. The silhouette would be similar to whatever model it's supposed to be, but the geo would be entirely custom.