So, at work we have a full body laser scanner that lets us produce a 3D model of a person, which I can then scale to any size. And there's this company called Shapeways that takes 3D models and prints them.
They should take paint fairly well, and there are other plastics shapeways will print in that are a bit smoother. They cost a couple of dollars each at miniature size.
Anyone interested in heading down to Providence some weekend and make miniatures of your larp characters?