From what little knowledge I have in 3D printing using the better material will take care of the lines and if you have all the different face expressions a 3D scanner should make a pretty good fitting piece and with the 3D software you could scan an existing face and then with your computer change the expression before printing.
Ripley, let us know how you mold making adventure turns out.
Ripley, let us know how you mold making adventure turns out.