Quote - ...I just wanted to comment on this, because your first assumption (for the second comment, above) was that the ray-cast was generating those bad eyelid results, but don't forget that it was where the ray-cast failed, in that case.  My point is that you seem to think (or it can be misread) that the current averaging may not be desired (or may even be specifically NOT desired)... my opinion is that it IS helping.  In other words, it IS being done with some care and in an attempt to refine the situation.

Feel free to try whatever you want now though - I'm anxious as always to see any results (and also curious to see if any of those poor results were actually just dropped verts).

It's very obviously helping.  I still wonder how sensitive the averaged normals may end up being to sampling errors for a vert in an odd position near a crease, either concave or convex.  Depending on the mesh structure in that area (and any comparison re-shaping in use), the candidate set of close vertices may contain too many normals which point one way or the other, so they don't cancel out and point in the middle, but in one direction or the other.  This wouldn't be disastrous if the surfaces are closely matched, but an askew normal will be increasingly off-course the further it travels.  I confess that I still wonder if this is why the raycasting is missing the current vertices.

I didn't mean to suggest that you were being careless, no.  I just don't trust the inherited normals, if there's any possibility of controlling the vector path we use for the normal, as with my suggested use of the delta as a normal.  I'm not sure we can expect normals and coordinate positions to average out equally well.

I'm not being critical.  I'm trying to think about ways that the process can be more tolerant of imprecise surface matches.  The current approach is great.  :thumbupboth:   Can it be better?  That's what I'm wondering.

===========================sigline======================================================

Cage can be an opinionated jerk who posts without thinking.  He apologizes for this.  He's honestly not trying to be a turkeyhead.

Cage had some freebies, compatible with Poser 11 and below.  His Python scripts were saved at archive.org, along with the rest of the Morphography site, where they were hosted.