I've been looking into all of the subD and sculpting software. Many of them could provide much more detail than what I can get out of the relatively simple subD like tools of T-Splines. The issue is getting them out of those programs and spanning the great divide into CAD. Plug-ins for Modo make it fairly easy to convert to NURBS, but that doesn't really have the tools I'd like to see to handle drafts and other components of making a mold. We also need to be able to work with supplied mesh animation files and convert those to CAD data/molds. Right now, we are seriously looking at Geomagic Freeform Plus. It's really expensive, but seems to be the only thing out there that is capable of bridging the gap between the visual 3D world and the CAD world and can create complex organic shapes/characters that can easily manufactured.