Since I get so many requests asking how I do it, here ya go! Listen to me mumble through a tutorial. It's a little long, but hopefully it'll be helpful.

Programs used:

reconstructme.net
netfabb.com/basic.php
meshlab.sourceforge.net
meshmixer.com
pleasantsoftware.com/developer/pleasant3d
blender.org
replicat.org
thingiverse.com
makerbot.com

Matthawk: thingiverse.com/thing:19118

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