... i'm trying with LOM-fabbing or laminating thin rectangular sheets of material and cutting only the contours and some additional lines in the outer area for dismantling the object from the surrounding material.
For this i made an 'inverse' STL, where i constructed a cuboid embedding the object and skeinforge 'filled' only the outer areal with honeycomb lines.
As result you would receive a block of stacked sheets where by breaking through the honeycombed outline you will unwrap the inner object.
This will be as strong as the sheet-material with the adhesive between ...
Viktor