Here's how it worked:
1. I'd have avatars come meet me in my "studio" - a floating cube with very basic geometry that was way up in the sky away from other objects.
2. I'd use an app called OGLE (OpenGL Extractor) that was developed at Eyebeam to extract the avatar's geometry and textures.
3. I'd then load up the 3D capture (which would be a mess) and clean it up and make a bunch of manual modifications to make the 3D design print worthy.
4. I'd export the resulting image as VRML and then send it to my printing partner who would print them on "Sandstone" - plaster infused with color inkjet and something like superglue.
Here's a picture I found on Google of them: https://farm2.staticflickr.com/1102/1236026167_49aae2fc0b_b....