This project produced a nice lasercut silhouette of Baymax. In addiction, more holes were added for the armor, embedding one inside the other. In order to maintain a largely landscape aspect ratio, the logo for the movie was also added on the side.
From the beginning, it was clear that there were going to be many, many dots: many more than are amenable to manipulation in SolidWorks. Instead, a vector based drawing program was used, called Inkscape. Inkscape, in combination with Adobe Photoshop and www.rasterbator.net were used to trace the silhouette of Baymax, and then obtain a halftoned version of Baymax with his armor on. Getting the halftone just right in Photoshop took a significant amount of iteration: continually tweaking the contrast, brightness, and overall lightness of the red vs blue in order to finally arrive at a solution that gave a result that was amenable when put through the Rasterbator. After obtaining a PDF from Rasterbator, the image was opened in Inkscape, converted to a vector, and then masked with the silhouetted image that was created earlier.
Here are the step-by-step directions to get a satisfactory result: