Do you use any 3D scanning software? You mentioned starting from files used to develop model cars. How hard would it be to scan a real part, generate a model, then clean it up in your CAD software? If it was relatively easy, your dream of building a CAD model for each of the 10,000 parts in your car could be closer to reality.
I'm ignorant but know there are many software tools that combine 2D scans/images of a part to generate a 3D model. For example, I have a Microsoft Kinect and PC interface. I know they have software to use it for 3D model generation. Might be fun to play with. I suspect there is way too much geometric distortion in a cell-phone camera but maybe not if you can "adjust" the imported model in your CAD world. To me, part designs back in the sixties and seventies were based a lot more on simple and "true" geometry (lines and arcs) than today where NC tools can follow geometries a lathe and mill never could. This might make it easier to make an accurate model as you did by direct measurement of your knob.
I always stop going down this mental path when I see the cost of CAD software like your Inventor....
Mike
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