Here's another insight in how I simplify a 3D model so it will make a better papercraft model (imho).

As you can see by the number of pink lines and dots, I usually get rid of a lot of the 3D detail.

This might seem as a shame to do, but think about it: in the 3D model, to create a smooth curve, you need to break down the curve into a lot of small straight lines, resulting in a lot of small polygons.

While with paper, you can just use one straight pace of paper and curve it all you like. That's how I try to simplify the 3D model: as if it isn't made from digital polygons, but from paper.

Another thing you can easily simplify are "double layers". Sometimes it looks better if you keep them (like I did with the armor pieces on Link's "man skirt", but take the head for example: [link]