I'm in the process of making portions of the caverns below Jorgenfist. I'll let you know how it goes and give any advice I come up wiht.
I've been wanting to make 3D tiles also. We're still new into this campaign - have just finished Glassworks, which would've been a cool one. I ran out of time to make Catacombs, and we alternate locations across the state, so not sure pack & travel would bode well.
I've found some cool player made stuff (just pics) on google, but I'll come back here and post pics if I make anything and to check if anyone else has.
Tabletop miniature terrain (for games like Warhammer, WarmaHordes, Flames of War, etc.) has lots of great tips on materials to use for your dungeon tiles, techniques, etc.
Good luck! :D
YES! I have made a lot of the terrain myself. Built the Glassworks with some cardboard. Made the Catacombs with my own generic dungeon tiles. Built Thistletop as well with generic tiles.
The Skinsaw Murders stuff was all built with generic "popsicle stick" wooden floor tiles (lumbermill, sawmill, Manor, Townhouse) as well as the Graul house/barn. Made some "corn fields" for the farms along the way. The clock tower I built myself too and came out very nice.
Fort Rannick I built using some pdf terrain I printed off and stuck to cardboard. All were easy to do, just took a little time, but since we only play about once per month, there was plenty of time to get to it all. Players have really enjoyed the stuff so far.