One last update before I order the parts! Here is the full thing as of all the most recent updates to the model.
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First off, after the other member did some testing, it's looking like the electronics package will now include both a revolving blue light and sound recorded straight from the show! I recorded the sonic noise from the end of the series finale and looped the latter portion on itself for extended play. The sound chip being used allows for about 20 seconds of play then the sound will end so it won't loop indefinitely (this way if the switch get's flipped on accidentally, it won't stay on) but I doubt anyone is looking to leave it on for that long.
It will work with a two-way slider switch so that when pushed all the way back, the lights and sound will activate - then when pushed all the way forward, everything will turn off. It functions this way due to the distance the switch actually travels across the face of the switch plate (so as to be accurate to the prop) being less than the distance the switch component travels from front to back. The switch is designed so it can be inserted at about the mid point but can't come out when positioned any further forward or backward from the center point. What this means is that the switch and mechanical bits on the sides would all have to be removed in order for the front end to come off - access to the batteries, however, can be accessed more easily with a twist lock back portion as I mentioned
earlier in the thread. I've redesigned this as well so that it's a double-peg twist lock (was single peg before).
Second update is I made the knurling more subtle. Before it was straight cuts but I rounded it out so that it will appear more as it does in the show, as a texture rather than a significant physical cut-in.
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Third update is that I decided instead of the brass rod features that hold the mechanical bits together being recessed, they're now protruded to be easier to paint in order to differentiate them from the metal bits.
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At this point I'm confident that I've done as much as I can before actually testing the physical prints so I'm planning to put the order in tomorrow. I should see them within a week or so after which I'll test the fit of the electronics in the housing and if all goes well, should have a finished, painted, assembled and fully functional sonic to show off and will shortly after make them available to order on Shapeways. Barring any unforeseen setbacks, it's looking like a end of January availability at this point.
I'll also gauge the time it takes to do so and price out a fully finished sonic for those who've expressed interest. While the kits on their own will be available indefinitely, these will be a limited run - subscribe to this thread if you haven't already so you don't miss out when the sales thread goes up - I will only be doing one run of them!