I'm new (ish) to the forum. I've been reading and learning and thought it might be time to give back.
Here is a project we did out of EPS foam using Cut 3D.
The video summarizes the process we used. http://www.youtube.com/watch?v=I1Of8WJPUWw&feature=related
The soldier was sliced into 2 parts (Front and back) and each slice was 8" thick. (actually, there was an extra inch where his hands are, that we just couldn't fit within the 8" so they had to be added later).