Not cureently SW-related (even though Airfix did produce SW kits back in the day) but I was reading on how Airfix will be introducing LIDAR scanning to next year's models (2015).
LIDAR uses light and radar technology to scan a fullsize object then reproduce it as a high-def 3D computer image. This will replace the present technology of using blueprints and photos on which to base their models upon.
From what I've read this is different to 3D printing.
IPMS Scale Modelworld Announcement
The story in the newsletter link above about the scanning of the WWII German Heinkell plane found crashed in Norway is interesting as Airfix designers were able to create a more accurate model than their original drawings showed.
They also made scans of the only surviving example of a WWII Defiant interceptor plane, and also Sea King helicopters due to their existing model and tooling degrading.
I don't know much about this technology, but I wonder if it's possible to scan something much smaller, say, a Kenner Millenium Falcon, or even the ones Airfix used to produce, and make a new mould based exactly on the originals
thevintagetoyadvertiser.org 1970s and 80s vintage toy ads and other retro paperworks
imperialgunnery.com Vintage Star Wars action figure weapons and accessories guide