Great work on your plugin Gandolfo. It gives very usable result compared to smash. But to cut this from paper would be dificult to me. And cuts seem to randome so I am not sure how smooth it will look when assembled. From this standpoint, I would probably prefer Zathros strips solution.
I would personaly do it as plane and boat designers do it (Zathros already demonstrated on a boat hull few post earlier) - I would remodel it: cut it perpendiculary and connect by stright sections, so it unfolds easily:
View attachment 159623
I understand that you are trying to avoid remodeling the part and work with souce mesh directly.
I am looking forward to see some test build of your unfold part. I hope you proove me wrong.
That' another miss-understanding, it can also be cut into strips! If I had the time I would do a step by step. It is actually exactly the same thing as post
#193 and #195 .. but it is NOT a poly mesh but triangulated mesh that can be textured and manipulated outside of Rhino! Think of it as Beta -.001 in a new Beta progression. When I say Textured, I am looking for a
Photo-Realistic approach ! I love what other people do and I am not knocking anyone's work but most models are NOT textured just color filled!
ie:
colored

textured!

90+% of Models are only color filled with a bit of gradation and few lines and such, and that is JUST FINE ! but it is not what I WANT! I WANT QUALITY! or it's not worth doing! ( I MY OPINION)
Now saying that, doesn't mean I will succeed! I am only trying to obtain that level, with programs that do NOT want to cooperate and are not designed to function in that capacity! I still have the model, cut up and flattened and at any point when it seems that all avenues are dead-ends, I can revert to the what the rest of the fine model makers do and just color in this thing with some fills and gradation and let the builder paint it.
It's like almost all aircraft models, why have a flat color and a few lines and rivets when with a little work you can actually make the model look like it just flew in from a sorte,

Rant done! Got tons to work on...
PS. I think that if you go with the thinner strips it will be a mistake. Strips OK but not hairline, if it is to be ONLY for a few of us , fine, but for the community, NO WAY!
Even the last pix from post
#191 is on an A4 sheet and scales out to about 6" just for the top of the head piece! (And it alone will be extremely difficult to build, it needs WORK!!! ) That would make the rest about 1 meter long at a rough guess, and cutting to fit on A4 sheets would push pages upwards to the 30's, again at a rough guess. The head is going to determine the overall size of this, therefore it has to be as large as feasible and as small as build-able and there is a VERY fine line there . The rest can be interconnected between sheets if necessary but that needs to be as limited as much as possible as it leads to problems with alignment and printer error and all manner of headaches! There is going to be a GREAT deal of COMPROMISE and SACRIFICE, in size and smoothness, to make this a model that the community at large can build! If it was just for the 4 of us that have shown an interest, I would have gone with Zathros's idea and just built the thing already!