Mimbo is a friendly robot who mimics your emotions/expressions. He has a cardboard box for a body and an iPhone for a face. See him in action here: http://www.youtube.com/watch?feature=player_embedded&v=csYPpxBOBCA
The body is made from a single sheet of cardboard and is folded and hot-glued to form the 3D shape. It was designed in 3D in Solidworks and flattened using the sheet metal tools.
The iPhone display is controlled via a Processing script that controls a TouchOSC interface running on the phone. Face tracking is used to sense the user's emotional expression and mimic it.
Full instructions on how to go about the coding part are posted here: http://www.instructables.com/id/Mimbo-A-Friendly-Robot/
Print out the .DXF ensuring that you keep the scaling constant. (You can do it on four separate sheets of US-letter paper.)
Glue the pattern onto a nice, clean peace of cardboard.
Cut it out using a sharp x-acto knife.
Score the fold lines lightly and valley fold such that the pattern is on the inside and the clean, untouched cardboard is left as the exterior.
or... disregard all of this and just lasercut the thing and it'll be perfect :)