3D Modeller to build robot head

I have a robot head designed which I'm intending to turn into a wearable head. Its of moderate complexity. My goal here is to 3D print this using Shapeways, so there a couple special concerns here. 1. Printing cost is high, so the model needs to be broken up into small parts that can "snap" together so I can print out a piece at a time. This will also help cut down on costs if there is an issue with any one piece. I'll be expecting you to separate the model into these pieces when you build the model. 2. The model needs to meet all the criteria to be printed by the Shapeways 3D printer (ex: must be geometrically sound). The model also needs to be thin and hollow where possible to reduce printing costs while still being structurally sound. Please share some recent examples of your work, and thanks in advance for your proposals. Also, be sure to let me know the 3D program you'll be working in (Max, Maya, etc). Thanks!
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