Hey Thomas,I love the experimentation. I can't tell how you start out this model but have you played around with ShadowBox at all? http://www.youtube.com/watch?v=Z3I7Epmbd0QEat 3D also has a really good DVD you might want to check out. http://www.youtube.com/watch?v=_xOKVGbZmEcYou might also want to check out T-splines. With a little retopology you can get your models into parametric CAD software.
I have tried shadow box but was not a big fan of the interface. I like dynameshing primitives together cutting slicing and pinching etc to shape the forms.. We purchased the eat3d training which was awesome and that ave us some hints but a lot of the techniques were not quite controlled enough- I found a zbrush artist in atl named Sam burton who came in and taught us some very applicable hard surface techniques for traditional industrial designed products
Always great to hear from you Andrew:) hope you are having fun :)
My friend who runs cadhuman.com uses t-splines to convert zbrush sculpts to cad formats
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