Is Kinect data high-enough resolution for your needs? I haven't played with it myself yet, but it could be one avenue to look into, though I don't know what sort of point cloud resolution you can get out of it. edit: Just found these two things:…
Y'know, it occurred to me that you could make one base head to spec, unwrapped and all, then shrink wrap that to each head that you get from the 3d scans (whether via Kinect or otherwise), and bake the diffuse down from the scan as well (and then of course do some cleanup on the texture). That way you're not worrying about…
Going the Kinect route would be great, since we get realtime feedback. I'll see if I can wrangle work into getting one. Taking the snapshots for the 3D stitching apps has been a pretty cumbersome experience so far... Oh and the final result should be in the ballpark of <1000 tris, 512x512 diffuse only. So we're not after…