Thanks for sharing your ideas!
On the 3D printed option, I haven't yet found the printing service in Europe that should be used. in Shapeways, there are basically two options:
"Fine Detail Plastic" that is their resin-based plastic. Supports wall-thickness of 0.2 mm
"Multi Jet Fusion Plastic PA12", or nylon (slightly stronger than ABS of Legos). Wall-thickness down to 0.5 mm
If you look at the geometry of Technic axle, the wall would be approximately 0,5 mm at smallest with the 2 mm shaft hole. So technically both would work.
I probably still go to the resin, as it's higher accuracy.
If anyone has tips, please let me know. I'll probably make the design available in Shapeways if this succeeds.
Best,
H