That really is impressive. I cut up the Klingon piece today. Just working on how each unfold, and seeing if it is plausible. I believe bulkheads will be necessary. The unfolded pieces are put together, virtually. Making such a compound radii part is quite difficult, it may not be feasible at a small scale. Not impossible, but not for the faint of heart! We'll see.
that's a lot of little pieces! im not sure that I understand yet. I would like to see more of the process please. sounds fantastically complicated, but maybe fun to do. like welding plates on a battleship. intriguing.
I'll try and get you more to wrap you head around it. The numbers are for instructions, and it just means, connect sides that have the same number. What I do is connect the parts after unfolding them. Wen they become something that intersects onto itself, you start a new section. At that point, you leave fewer "Dots" to show how it goes together. I really think that this would have to be a good size to be viable. It would be better to shave down a foam ball, and cut these out as plating to glue on.