Customized GI Joe Action Figures: 3D scanners put your face on Destro's body
replicatorinc.com
replicatorinc.com
You could probably have about 100 heads per gender with several hair colors and styles each and be able to pick one close enough to fool all but the pickiest of eyes.. and it'd probably be cheaper than customized fabrication too ;-)
Still, a cool idea, but I can't help but wonder if they're too accurate, you'd end up with an Uncanny Valley type effect.. http://en.wikipedia.org/wiki/Uncanny_Valley .. who wants to play with a figure that looks just like someone you know (or yourself)?
I love GI Joe toys. I still preserve my collection like pure gold. The only time I lend is when a kid comes to my house. Just spreading the feel.