Dan,
The software isn't an issue. You can get Rhino or SolidWorks student editions for around $100, and probably Inventor is available in a student version as well.
I submitted some parts today to see what the results are, including the heavyweight ice bunkers and the next C&O well car prototype (with a FUD body and SS underframe). Based on how the ice bunkers look, ESM might go that route since the tooling price was higher than expected and the demand doesn't figure to be extensive enough to warrant it. This process may accelerate some ESM Sovereign Modeler projects as well.