Has anyone else tried using Art Of Illusion? I've started using it to design card models. I used to use a program called MoRay, but when I was forced to switch to Vista, the software stopped working. I tried blender, but as others have said, it has a steep learning curve. Anyway, AoI can export into .obj which pepakura seems to import ok. It also has some uv unfolding features that I have yet to try. Right now, I'm following the AoI tutorials to learn how to create per face/per vertex textures.