I once had a vendor come to the museum to demonstrate expandable foam packages. The packages contained the foam components and you ruptured them, then let them expand around your object in its crate. Our collections were mainly two dimensional so we didn't try the product.
I would worry about undercuts, negative spaces and such on the sculpture and wonder if it could be done in sections like you were making a mold? Maybe the foam could be sprayed into packages, like a heavy duty leaf bag, which then expands around parts, but is removable. You may not be able to save and reuse the sections for the return trip however unless they were somehow marked. An experiment may be in order.
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