Just to save you time: this process has taken ages to work out and slight variations often don't work...
The toolkit is a head! plus a camera, the internet (you really need this), a computer, Autodesk 123D, Autodesk 3DS Max, Pepakura and Adobe Illustrator.
You also need a color printer, preferably a plotter and if you really want to get moving quickly a laser cutter.
Step 1: 123D Catch
Using the browser based 123d catch (not the standalone app as you can't get the files out!?!?) upload the images (delete blurred or dark ones) and wait..... When the 3D model has been created download the OBJ file that is in the "Save/Download" menu and it's called "Download (Mesh Package File)" The website is confusing and you can easily end up in the wrong place.
You can edit the file in 123D but it is much quicker to go to the next step.
My file is here: http://www.123dapp.com/FullPreview/Index.cfm/ID/1272520
123D Catch Photo Tips from the Autodesk 123D website.
1) Avoid Symmetry or ambiguous features in photos
2) Accessibility – Is there enough space around the subject to make the shoots? Start from the center and take photos on every 5 or 10 degrees.
3) Avoid Occlusions, if it is not possible take more photos 4) Photographs need features (They can’t be transparent, “super” glossy or reflective)
5) Subjects cannot move
6) The software will use the maximum of 70 photos and it is recommended to shoot at least 50
7) You need a consistent lighting (not underexposed or overexposed) – Overcast day has a nice lighting consistence.
8) Do not use Flash
9) Focus your target model (never blur it) and if you use depth of field to blur the background do it in all your photos
10) Photos resolution don’t need to be ultra-high because 3 Mega Pixels is the highest resolution the software will accept, otherwise 123DCatch will resize them.
11) Consistent Orientation (portrait photos or landscape)
12) Do not crop or edit the photos