Some work is required to lay out the model as economically as possible for A4 paper and to move the tabs into the correct places. Pepakura attempts to flatten out the 3D model into 2D parts that can be printed onto paper, these parts can be cut out and assembled. Once I had a 3D model featuring only the parts I wanted to build I exported in the 3DS format and opened it in Pepakura. I am sure this could be done in some of the free modelling packages that have cropped up since 3D printing came along. I used Cinema 4D for all my editing because that is the modelling package I know from many moons ago. I removed all of the inner skin so it was quicker and easier to build. The Helmet was built with an inner skin and an outer skin to give it some thickness in the model. I was able to select all of the body parts and delete them from the model leaving only the helmet. I was fortunate to find that the helmet was mostly separated from the rest of the model. The initial 3D model was a complete version of Hiro, body and all.
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