Re: FOAM speed building files'n'tricks ►Spaceballs Darkhelmet◄ added.
I don't relly know how I could explain it without making it sound like it's an evidence, but yes : two different unfolds are two different ways to dissect the model. It is in a sense the meaning of the term, and the whole purpose of Pepakura Designer.
To obtain some large pieces, you simply have to snap small ones together.
To do so under Pepakura Designer, select the appropriate tool by pressing Ctrl+N, or by a right click 'Join/Disjoin Faces', or by enabling the zipper icon 'Divide/Connect Faces' in the toolbar. Once done, you can split a face along a green line by a simple click, or join two faces along a red line by a double click (or simple click here too if working directly on the 3D view).
Before starting clicking everywhere, I suggest you to take the time needed to figure out how you plan to cut up your model, which surfaces will remain in one piece, and where to join the different pieces for the seems to be the most discreet as possible. To visualize the model clearly and noisefree, I usually set temporarily the view as follows :
3D Menu / uncheck 'Show Edges', then 3D Menu / View Setup / Display Setting / Shade ON, Size of Openning Min, and Viewing Angle cursorbar at full right. At this point and if you wish, you can use 3D Menu / Edit Mode / Open Edge to mark the edges you want to appear disjoined after the computed unfold (needs to enable Show Edges).
For a foam unfold, you'd rather hide all the way Flaps and Edge ID through 2D Menu.
The fail/win setting of you unfold will all depend, of course, of your flair to determine the appropriate way to join or disjoin such or such face to or from its neighborship, or which faces you can exclude from the final templates. It may be long because you'll have to process with each and every face.
It's more or less the concept.
In one word, you have to imagine you're building it for real. The main idea is you must at first build your model out of foam in your mind, and identify the easiest way to go. Then use pepdesigner to draw the templates you selected.