@Ross: Take a look at Mesh Fusion over there with Modo. If you already have Rhino then I find Modo brings to the table all that T-Splines does and then some. And yes I make things that can be manufactured from it. Maybe this is just my approach but this kind of old skool approach to having to build models into being is kind of counter. SubD for creating organics is much more intuitive than wire frame. And especially now that dynamic systems are becoming easier to use why not let or at least start from that point.
Image just dropping a soft leather cushion and it deforms they way it should. At least its a starting point to then sculpt in any additional details.