I do that with any tool cases I need to have at a long-distance job-site. 

Not a big fan of explaining myself to the rocket-scientists that TSA hries.

I once tried to go to a visitors lounge in an airport with a phillips and a flat head screwdriver on my keyring, little key shaped ones I forgot they where even on there .. talk about third degree. Apparantely I could have unscrewed the windows in the lounge, escaped onto the runways and started dismantling 747's before they could stop me..

they can be buttheads.

If you have any reason to think what you are carrying might look suspicious, no matter how innocuous it really is, getting all in a wad over it just makes matters worse and triggers behavioral alarms.  Better to acknowledge to them 'hey, I know this might make you go "hmmm", I can explain', and be upfront. 

And of course, plan extra time just in case you get the rare unreasonable one in the bunch.  Despite all the stories, they're just trying to do their jobs and don't like being buttheads about it, for the most part.  'Course you can always catch them on that bad day, or be unwittingly traveling at the same time as they get some sort of specific alert of decree from above.

or you print something that you'd have to be a complete idiot to want to take to an airport (pretend gun/knife/bomb/grenade/RPG/etc)

Words of wisdom, last time I brought an rpg to the airport things didnt go so well.

Now if you made a hollowed out oregano holder they might be more than a little suspicious.

i know they shouldnt hassle us about it.  but there are alot of stories out there about tsa going way beyond what theyre suposed to do.  thats what i was wondering about.  if anyone has gotten on with say one of the coin bottle openers or such and gotten hassled.

Why are you asking, just out of curiousity?  What to you need to carry on that you've printed that can't go in your luggage?

I can only see a couple of times where this might be a problem.

if you create a shape with a very low infil and therefore lots of hidden voids show on the xray that you've packed with drugs.
or your infil creats a pattern that may be mistaken for a vegetable matter, or pills.
or you print something that you'd have to be a complete idiot to want to take to an airport (pretend gun/knife/bomb/grenade/RPG/etc)

The solid vs. air space will barely show any contrast at all on an X-ray.

Fuggetaboutit.  It's not an issue unless you're packing something much more chemically reactive inside the gaps (not going to be any more suggestive than that).