My teammate and I started by gluing Finn to the bottom of the box to prevent him from moving around and we used spray foam directly in the box. In order to reduce misshaping the thin cardboard box we wrapped it in masking tape and marked the centre line for cutting on the exterior before spray foaming (ALSO we left the top open to allow for the inevitable  foam expansion).

We were fairly successful at cutting the toy down the centre and from there we decided on which side would be horizontally or vertically cut based on the arm angle (the one piece which is asymmetrical). Cutting our slices 1 cm each was a decision we made to get enough cuts to get detail but not too many cuts which would lead to too much material loss.

Now we have SCANNED them to reduce scale or angle variations that would come from using a camera (after the fact we are rescanning with a ruler to insure the correct scale).

Now to Rhino tracing!