Dang, that's no good, Dave. We're having budget cuts too but so far not that dramatic, though I'm not completely sure my program will survive long-term, not in its current form at least. Good luck, make them pay you more...
Your problems mirror mine. I've had two parts the same arrive in the same order, and one was fine and the other, not so much. Very stupid orientation issues in another case. Etc. I checked on the Shapeways forum and there's a lot of similar complaint there from other users.
I've calculated a total spend for 3D print items of almost $4K. If there was a home 3D printer on the market which was:
a) reliable
b) capable of 0.2mm resolution or better
c) capable of printing thin parts in a sufficiently strong, non-proprietary, inexpensive material and
d) able to handle a build volume of about 30 x 25 x 20cm or better (45cm would be *awesome*)
then I'd be buying. Anything under five figures, I'm in. But nope, you have to go up to the large pro Objet units and their like for that.
My next sets of parts arrive next week...I'm kinda dreading it; if they're bad that could spell the end of this project, at least temporarily.