This is a great idea. I also think to do things like this, to create some kind of masters via programs like sculptris or blender which both are free. I hope to get a 3D-printer within the next half of a year.
Best regards,
Erhard

Well, for reasons of easy glueing part together, I generally would prefer plasic of the polystyrene type as used, e.g., by Preiser. They achieve superb results meanwhile in their 1/72 range (see www.plasicsoldierreview.com). The soft type of plastic as used by Zvezda (and a similar type by Pegasus) is better since it allows small undercuts, however, you have to use this cyano-acrylate glue if a figurine has to be composed of several parts (the new set of Swedish artillery by Zvezda shows the detail you can get with this material). In all cases, the mould production process is quite expensive and only useful if the output of figures can be big enough.