I tried PatternImage but couldn't get it to work. Any ideas? There Must be something out there.

Blender is a free 3D tool and there are lots of tutorials available online that teach you how to build a 3D model from your drawings. You can then take the 3D model and "unfold" in either manually in Blender (I don't recommend this) or use software like Pepakura Designer to build a pattern from it.

Here's an example of someone who did a project like that:

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https://youtu.be/-WBGxLB2NEg

Honestly though, there really isn't a good way to generate patterns automatically. In theory at least there are a lot of ways you could build a 3D model from your drawings and then flatten it, but I don't think the results will ever be as good as what you get from trial by error and doing it manually.

What type of shape are you trying to pattern?

I'd really like to be able to put in any design. I really don't have any problem working on a single head from scratch, I'd just like to streamline the process.

I am curious why Pattern Image did not work for you?  It is doing the same thing as Andrew mentioned above really.

Actually, truth be told, after I downloaded it, I couldn't get it to boot up. That's why I couldn't use it. Have you used it? Or do you know of anyone that has?

Well I am not sure about the current version offered in the link I posted, but I know when it first came out a couple folks played with it.  I spent about a day playing around with it but like Andrew said it just does not seem to take into effect the challenges of puppet making.   I think maybe it might be ok for figuring out simple shapes and how to pattern them though.

I'm not sure what your needs are but perhaps you're trying to reinvent the wheel a bit. Have you tried Project Puppet? They offer some great patterns that serve as an excellent launching point. But when it comes to making your own patterns the Play Soup series that Dave Privett put together are an excellent tool! In them he teaches you how to take ANY original design and bring it to life as a puppet, making a pattern along the way. Unfortunately I don't think there is an easy way to just take a design, plug it into software and have it generate patterns for puppet construction. But let me know if you find such a thing!

The Play Soup DVDs are a great suggestion. There really is no substitute for learning to pattern properly. I personally find Dave's methods slightly more complicated than they need to be, but his DVDs are probably the best tool out there for learning how to make original patterns.

Thanks, Andrew. I think the DVD is the direction I'll move in. Original designs mean original patterns, at least to me. I think the Project Puppet patterns are a goood idea and all, but I think I want to own the pattern and therefore the archetype.

I agree Andrew that Daves' methods can be a bit complicated (Man his eye mech is WILD!) but as you say a great place to start. And I wanted to add that Daryl over at StiqPuppets covers making a puppet from an original design in his video series. I don't recall if he's covered creating a pattern for an original design...yet.
http://playsoup.com/store/video.htm
http://www.youtube.com/user/StiqPuppets