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Regarding an engine to look at, where has the Champlin Museum Pfalz D.XII gone to after it was sold?
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The Champlin Pfalz went to the Museum of Flight in Seattle, WA.
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TurboCad will also export to STL but I am uncertain about the issue of 'holes' in the model surface. Apparently this is an issue with the 3D printing process. Often the people who produce the models have to fix a customers STL files beforehand. There was a feature article about this topic in '3D World The magazine for 3D Artists, Issue 97, December 2007'. You may be able to find a copy. It was still on the news stands here last time I looked a few weeks ago. Failing that, back issues are available through the publishers web site http://www.3dworldmag.com/
3d printing is not cheap, around US$250+ per item last time I looked.
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I'll have to get that copy of 3D World. My impression of 3D printing is that it's still immature technology -- can by done, but pricey and requiring specialized expertise. In another 3 years, it'll be much improved and in 5 it will be a consumer technology.