3D Printing Hexagon Models
If anyone is looking at buying a 3D printer, I can verify that Hexagon works just fine for creating models to print.
I model at the scale of 1hex unit = 1cm then export to .stl with a scale factor of 10, the units in the export dialog don't seem to make a difference to the size of the exported model.
Then using ReplicatorG I create the G Code and export to .x3d and stick the file on an SD card to print.
If you use the chamfer tool in Hexagon to create rounded corners, there is no need to do anything about n-gons, as long as the mesh is tidy - the exporter seems to triangulate the mesh OK, though you might want to 'quadify' it yourself.