I do test prints for a few reasons:
1. Printablilty - does it survive a print without getting distorted or broken, does it polish well etc.
2. Presentation - so I can get photos of the item. This also covers differentiation (from the many products that aren't presented well), and proves that I'm happy to invest in my own stuff.
3. Design quality - is it actually as good, once realised, as I thought it would be (things look very different on screen than they do in your hand) - _does it work as an object_ rather than as a 2d pattern. Have I got the scale or proportion wrong, are the points going to catch on things, etc. For stuff that fits together this'd be really important.
Point of fact is that I don't test everything - with co-creators it wouldn't be possible, but I have already tested that the basic design worked. But this too is open to problems - I had an issue recently where I had an order (from outside shapeways) for a really small polyoptic ring, about half the size of an "average" one, and once I'd had it printed, it was had a very different quality than a larger one. Not just in the sense that it was smaller, but that it seemed so much cruder because of the resolution of the print was relatively lower, and it hadn't been polished very well because (I guess) it was hard to hold since it was so little. It wasn't all bad, but my heart really fell when I saw this little lump of metal drop like a rotten tooth in my hand, instead of a big lovely shiney futuristic cloud like I expected. I expected just a scaled down version of the other ring, but the process doesn't scale like that, and I didn't (and don't) know enough about it to know when things will work or won't.
But it did mean I had a reason to go out and buy some good polishing stuff and eventually got it looking nice, but it taught me a little about what caveats I should add when making promises about being able to make things "in any size", and what the limitations of the process are.
For metal, I think consistency is a problem, but that's not something we can really test for. I ordered two rings a few weeks ago, and I imagine they were printed in the same batch, but one is good and one isn't so good. Not bad, but just not as good as the first. I'd be _really_ interested in being able to specify a finish quality (how polished), and wouldn't mind paying a little bit more for a good silver grey print, well polished. If I have surface details I realise this is impractical, but I don't.
In the plastics, I'd have no fear at all about consistancy: Everything I've had has been outstanding.