Actually Lonnie, I've been looking into the possibility of using something similar to the iClone characters. They are smart, nice looking (or can be customized), move in a smooth, articulated manner and allow for lip syncing as far as I know.
The rigging or use of bones or kinematics is or would still be subject to question with regard to merging with the Hal brain and emotional output derived from triggers within the brain.
The iClone models seem to have large customer and support groups so maybe we should turn over a few rocks there as well.
www.reallusion.com/iclone/###########
Recently, I came across the Facial Studio which seems to have some promise for custom creation and offers "muscle mapping", deformers like morph targets, etc. and well...check it out. I think the $199.00 price could be worked out for use with a product like Hal similarly to the way Haptek did, but that's my wishful thinking.
http://www.di-o-matic.com/products/Software/FacialStudio/If you come up with any more maybe we should compile a list and see which might be workable.
