I was part of a team at DesignSpark, tasked with sending a Superman figurine to Space in a SpacePod, then have him 'jump out' of the pod and free-fall back to earth. I was responsible for making a SpacePod capable of surviving the assent (-40C, wind, rain, cosmic radiation), and ensuring that the 4K cameras and GPS equipment all survived the 5m/s descent to Earth. (Other brave Superheros may apply).
I had recently just made a Card Rabbet Tool for making making fancy prototypes out of corrugated card... However, Card was not waterproof... luckily I realised that this tool also enabled me to work with Correx (like Corrugated Card - but made of out plastic, and therefore waterproof!). Correx also has a great strength to weight ratio and would absorb the shock of the landing. It was also cheap at ~£10/sq.m.
This Instructable starts right in at the deep-end, and give some insight into how to design something in CAD, and export it as a 'net' (2D template of a 3D form), so that it can be assembled from a sheet material. If you are new to using this tool, you may want to check this starter-guide out first. Once you have the idea, this Instructable can help you make a huge variety of forms, for prototype, architectural models, sculptures - and even Space Missions...
This SpacePod was designed in the style of Felix Baumgartner's supersonic freefall. Now, although this is clearly not as dare-devil as Felix/RedBull's efforts - what is amazing is the comparatively tiny cost of such a mission like this: Electronics that would have cost millions only a few decades ago are publicly available and ready to roll, from companies like Raspberry Pi [in the Sky]. It's inspiring stuff. For the full electronics low-down, read about it on the Design Spark blog, and video in Italian, here, but until you order your PCBs, do look through this Instructable and see how cheaply you can get a SpacePod together!
PS - Please vote if you think this inspired you to get more out of you favourite action figure...
UPDATE: Thanks for the votes! I appear to have made it to the finals of the formlabs competition - and bagged a super Instructables T-Shirt!