Pepakura is an exciting process! I would love to use it for a full character costume some day. Its a long process that involves Maya (or any polygonal modeling software), Pepakura, Adobe Illustrator, and Rhino. The cardboard is printed using the laser cutter. Assembling the pieces can be tedious but rewarding in the end. about 1000 polys in a human size sculpt took a while to build.
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