I've been tinkering with this same thing for a couple of weeks. By building overly large clothing figures in Wings3D, I've avoid the intersection problems. The image is one of the tests after re-importing the mesh. It works best if you build fairly low-poly meshes and use the CR2 method to make them into conforming figures. If you use Wings3D, you can take the .obj after posing, weld it and smooth it a couple of times to get nice flowing folds. In this case, I'd do another drape step after re-importing to get the mesh to sit better on the Poser figure.

The steps work like this:

1. Create the mesh in Wings3D
2. Slice it up into groups. I do this in Wings by assigning a material to each group then change the usemtl statements to g statements in a text editor. You could also create the groups in Poser.
3. Run the mesh through UVMapper to set the mapping.
4. Use QuickConform to convert the mesh to a figure.
5. Set the fall-off zones.
6. Conform the clothing and pose.
7. Export the posed clothing to a new .obj. Re-import and drape. Export the draped .obj.
8. Import the draped .obj to Wings to smooth. Export.
9. Hide the clothing figure and import the smoothed prop.
10. Drape again if desired and apply materials.

It seems like a lot of work but goes pretty fast after doing it a time or two. The biggest problem is making certain that pose is finalized before hand. Any changes
means having to pick up at step #7. Also, this works for static poses rather then animations.