Originally Posted by qubyts
Anyone out there with a bit of 3d software experience?
Yes, but realize that "3D" is a big world, big enough that there are specialties that hardly communicate:
- Art and entertainment (movies, games, 2D fine art...)
- Architectural visualization
- GPGPU: all the people finding ways to use the 3D graphics processors in PCs when they're not being used for games
Those of us with experience in any area but the last may not be able to help you.
What it comes down to, qubyts, is what format(s) your machinist can accept.
If he needs Pro/E or Solidworks files, you're going to have to find a professional in the field, because these packages start at about $4000, out of reach of any sane hobbyist. That would explain your lack of answers here: such a person who is interested in your project is likely to want to make a go of it all by themselves.
If your machinist is willing to accept faceted models, the rest of us 3D users may be able to help you. Or, you may be able to help yourself, with free software like Google SketchUp or Blender. Realize that the biggest difference with these programs is that they're not intended to produce manufacturable output. The thing is, because these other areas of 3D are getting so much bigger, a lot of manufacturing processes have evolved to be able to accept them anyway.
Before you ask, no, I can't make these files for you, regardless. I had two pairs of Grados at one time, but I killed one and gave the other away. I'd need a set on hand so I could take measurements.