These pictures mark the culmination of my 3 pepakura project to date. The theme is a robot which is dissasembled on purpose. The continuation of this project is to use wires and lights to either suspend it in a workshop type atmosphere or to distress further and add attachments to make it look like a real robot being repaired. The pictures follow first from the modeling, to breaking it up in pepakura, to illustrator workflow and to the progress from unpainted pieces to a mostly assembled final silvery robot. There is more yet to come in this avenue of projects.
Tam
I began by closing the edge loops (always use edge-loop modeling for these forms), and then attaching all of these individual teeth you see here.
I then glued along the loops to finish each of the arches respectively. C'est fini pour maintenant.
And this is the produced abs printed fused-deposition modeling "egg" that was later painted to match the mettalic finish in the rendering previous. 
This following picture is a screen capture of the ideal of what the pepakura file for the final project could have produced. The final model is flawed and is not pictured here, but the synthesis of this idea will continue. Once completed, I will post again to show the potential of the idea being realized.
After letting it dry completely, and with minimal sanding I was able to coat the form with a smooth-on mixture to create a flexible mold.
This is what the mold looks like after complete drying to demold the original part. It is now ready to pour in whatever moldable liquid you might want to use, such as plaster, hot wax, or resin. This entire process doesn't need a mold release agent, and while messy, is less than expected.
