Pepakura

Pepakura is a method of unfolding a 3D digital model into flat, printable templates that cosplayers use as cutting guides for foam or paper builds.

Pepakura (short for the Japanese word for paper craft) refers to software and the files it produces, which take a three-dimensional model and flatten it into numbered, tabbed panels you can print on ordinary paper. Each panel corresponds to a section of the finished prop or costume piece, and the numbers printed on the edges tell you which pieces connect to which. Makers most often print these sheets, tape or glue them together as a test fit in paper, then use the paper panels as physical stencils traced onto craft foam or thermoplastic sheet before cutting. When working with craft knives to cut your printed templates or the materials you trace them onto, always cut on a proper cutting mat and keep fingers clear of the blade's path. If you move on to heat-shaping foam over the paper template, use a heat gun with care — point it away from your body, keep it moving so it does not scorch the material, and work in a well-ventilated area. Younger makers should have an experienced adult present for any cutting or heat-tool steps.