Pepakura (http://www.tamasoft.co.jp/pepakura-en/) is a program that lets you take 3D models and convert them in to paper craft models. It creates paper cutout templates with tabs and fold markings based on the facets of a polygonal 3d objects.
It seems like people have been using it for quite some time to create a base for Halo armor. Combined with a bit of fiberglass resin (or the recommended non toxic Aqua-Resin), you can build armor, weapons, and pretty much anything you can design in 3D. It takes a bit of work to get it to a finished product, but it's definitely cheaper than having a 3D printer.
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