I love what you're doing with the technology I may have missed it in an earlier post but what 3D printer are you using? Also what 3D program are you using to create them? Do you print them yourselves or are you sending them to an online printer like shapeways or one of those?
I make the 3d-models with Lightwave Modeler, prepare them for printing with Autodesk Meskmixer and/or NetFabb, print them with my Flashforge Creator Dual 3d-printer.
You can find my tutorials at:
http://puppet.tioh.de/