Hi Alex,
I just thought I would share my progress for the same endeavor. A few months ago I purchased a mesh for a Snitch model online from a place called
IncendiaFx. I slightly modified this mesh and had it printed at Shapeways in FUD. After the item arrived I determined that my initial size estimate was wrong (I tried to clarify in this
thread) with 1.25 inches being a tad too small. I also did a test to determine if it was feasible to print the engraving with the mesh rather than engraving it afterwards, I think it might be possible but it would be difficult to get good clarity and detail. The 3D print is really nice and detailed. I got stuck at finding somewhere that would be able to make a pewter or brass casting of the 3D printed model.
Here are some photos and my attempt.I think the ideal size is between 1.25 and 1.5".
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These are all the items that arrived from Shapeways. I designed a stand/sprue for casting and made the snitch hollow to save on costs. The little tubes are the wing nibs. The little rectangle is an test to see what the engraving would look like when 3D printed.
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Here is an attempt at a close up of the engraving test.
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Front of the 3D printed snitch.
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Back of the 3D printed snitch.
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Size comparison between the 3D print and the "sticker" snitch.