Some of you may recall me posting this thread from The Miniatures Page?

http://theminiaturespage.com/boards/msg.mv?id=341361

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Unfortunately, his project appears to be dead as there's been no update since 2015, but I do think this would work very well for Sails of Glory. It follows the some of the same ideas Wizkids had with their plastic pirate ships, but looks infinitely better in terms of historical accuracy.

Other options outside of 3D printing would include paper printing as War Artisan does on his 1/300 scale ships or laser etching of brass or wood to create 3D ships from 2D forms. In model railroading you can get brass car sides to change the style and road names of various stock and passenger cars. I imagine you could do the same to ships using a base hull and then applying laser etched sides to alter the appearance? Laser etching can deliver incredible detail even at small sizes, but I'm sure there's an increased cost the smaller you go?

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The major problem is finding someone who has the equipment, time and access to materials to get any of this going beyond general hobby interest.