Pepakura

Summary

Paper models, also called card models, "pepakura" or papercraft, are models constructed mainly from sheets of heavy paper, paperboard, card stock, or foam. - Wikipedia

Printing designs

There is one main program for creating paper models - Pepakura Designer which you can buy for $38. It takes a 3D model and allows you to define cut points, then unfolds the model to create printable templates. You can also find many templates online by just searching for Pepakura. The replica and cosplay community often use Pepakura as a base for their costumes so its easy to find lots of video game, fantasy and sci-fi templates.

Once you have your template and you have scaled it to the size you wish you can print it on Makespace's printer. I have printed on 160gsm card on the manual feed on the Lexmark printer with success. If you are going to use the vinyl cutter on your prints then see below before you print.

Laser cutter

It is possible to cut EVA foam on the laser cutter - to be experimented and written up.

Vinyl cutter

The vinyl cutter can cut your templates and score the fold lines for you. To do this registration marks must be printed to line up the templates with the cuts. When you lay out your templates in Pepakura designer, ensure that your print margins are 25mm top bottom and 15mm sides. The Vinyl cutter PC has installed Pepakura Viewer for CraftRobo. Load your template turn on the registration marks and print preview to ensure nothing is outside the bounding box of the marks. Then print out to the Makespace printer on card of your choice - I have successfully cut 160gsm card.

To cut your printouts (detailed guide here), setup each page on the backing sheet, then click cut pattern in the viewer. Click properties in for the craftRobo and ensure there is a cutline setting you're happy with for the fold lines. The software will then give you the normal CraftRobo dialogue. Select the paper type to be card with backing (if you're using card) and ensure that you've swapped in the yellow blade cover as it says. Hit cut and it will search for registration marks and then cut your page. Repeat for all your pages.

Making the model

Recommended approaches are hot glue or PVA.

Strengthening

A number of options which you can find lots of information online:

• PVA papier mache
• Glass fibre and resin
• Polyfilla/car body filler (e.g. bondo)
• Casting

These will all give you a surface you can sand and finish with paint.