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The answer can be found in a new Instructables by Damon Ahola, an MFA student at the School of Visual Arts in New York, that takes you painstakingly through a detailed process from design to print.
Ahola covers the initial concept, detailed design and 3D printing steps. It’s a simple process, but instructive to those who haven’t attempted something like this previously.
Ahola’s Instructable uses SolidWorks for preparing the 3D model and 3D printing on a MakerBot Replicator. If you use other software and hardware, this tutorial is still for you, since the general concepts and approach can be universally applied.
Via Instructables