Hi Grant,
I'm not sure what specific issues have arisen at Westlawn with regard to developable surfaces. However, I can refer you to two Rhino labs pages which might be of interest in this regard. The first is a tool in development called DevSrf intended to create developable surfaces between pairs of rails (say representing the sheer and chine or chine and bottom). The second is a tool for "flattening" surfaces. Here are the links:
http://en.wiki.mcneel.com/default.aspx/McNeel/DevSrf.htmlhttp://fr.wiki.mcneel.com/default.aspx/McNeel/AdvancedFlattening.htmlI would also add that we are working with McNeel to try to incorporate developable surface capabilities into Orca3D, specifically in relation to the Planing Hull Assistant.
Larry