the current reprap style uses all printed fittings for threaded rods. you could replace the horizontal rods with printed racks (http://www.thingiverse.com/thing:14537), but your xy precision would suffer. This is homemade, scrounged parts kinds of solutions. If you have access to a nice commercial printer, you can print everything but the electronics and steppers at very high quality. I don't think anyone prints conductive inks as part of the process. I think you can steal this inkjet print head (http://www.thingiverse.com/thing:5152) and incorporate it into an existing system without to much effort.
There's nothing standing in the way of starting with magnets and wires and a 3d printer for motors. you'd probably want some cleverly placed metal sleeves for heat dissipation.
The electronics might be really hard, but they might not. Lots of universities used to let EE students fab their own VLSI chips. I don't think it's outrageously hard, it's just toxic. a lot of this might be solved with cool inks. I know there have been a few printable electronics doctorates handed out over the years.
so.. not long. not long at all.
I have, but they kind of suck. my programming language snobbery makes it hard for me to use openscad. i keep meaning to write a haskell dsl to emit openscad, but i'm unbelievably lazy.
That said, there's OpenJSCAD if you like variables. And also, speaking of the devil, there is a programming language CAD in Haskell! It's call ImplicitCAD.
Would you ever have a need for visual source control for your 3D models? If so, I'd be interested in hearing from you. iamwil@gmail.com
https://en.wikipedia.org/wiki/RepRap#Construction
fingers crossed they get there.