I just found this thread -- it's cool to see what other people are doing at Shapeways!
I know I'm late, but as for the bendy parts, you could add sprues that are thicker than the part -- 3mm or so -- which sometimes seems to help keep things in line during the printing process. I would add to the leading and trailing edge. Connect them with .8 mm wires. The nubs are pretty easy to remove. Obviously it'll add to the cost of the parts, but may save enough trouble to be worthwhile. Also, you could cheat the overall thickness by .5mm -- not really that noticeable but could make the part a lot sturdier. Finally, I'd be tempted to merge all the pod parts to the wing. It'll also help anchor the wing during printing. I was initially making lots of small parts for my Cygnus build but found that merging the pieces can make them more stable and saves cost from the volume discount. Although you have to cough up more money at once for bigger parts.
Looking forward to seeing how this turns out!
