That's great to hear that the metal engraving came out great! Please post pictures! And yes it appears as though the metal printing process makes the pins slightly larger then they should be. I suggest taking a slightly larger drill bit and clean out the base holes.
You are absolutely correct. I am limited by what shapeways can do and it is to much of a low volume product to merit more expensive production methods. The smoothest finish you will have will be with the frosted detail plastic option. It will be transparent and smooth which will allow you to paint it with your own color choice.
