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Originally Posted by Max Lobovsky
How are you planning to turn the mesh into a part? Some sort of rapid prototyping machine?
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Exactly.
Through work I have access to an SLS (Selective Laser Sintering) machine. I can get 1 or 2 of something done for free by putting it in the extra space around the money jobs. If I have to build a lot of something, but not enough to make injection molding profitable, then I can rent time at a commercial service. For large numbers of small parts SLS can be affordable on a per part basis, if the parts are packed tightly.
While the calipers and 3d Studio approach might produce a usable product, it would take a lot of work to get it right. A laser scan like phrontist mentioned takes minutes and all of the holes at strange angles will be properly positioned. Why do it the hard way if you don't have too?