Quote - Very nice.  Can you do a test for me? Just below this line:

                    hitpoint = mesh2.mesh.CorrelateToNearVertList( vi, mesh1.mesh, close_index )

...try adding these 2 lines....
                    if not hitpoint.Valid:
                        hitpoint = mesh2.mesh.CorrelateToNearVertList( vi, mesh1.mesh, close_index, 0 )

...in other words, if it fails with the averaged normals, try again without averaging, then just let it fall through as usual.  The idea is that the non-averaged normal might get a hit where the averaged ones are failing.  If this gives better results on the eyelid area, I can do the multiple testing internally.

I tested the above and the results didn't noticeably change, compared to not using it.  I tested with influences = 5 and influences = 12.  The results worsened at the higher level.  This would be true when the second pass is not in use too, however.

I tested fully disabling the normals averaging, and the results weren't pretty.  :lol:  It missed the area above the eyelids, and it missed more of the vertices in that area.  Raising the influences may have helped a bit here, but not much.  The averaging is helping in this area, generally.

I tested my idea with the delta as normal, and it didn't turn out well.  So I can now stop dwelling on it.  I have closure.  :lol:  Thank you for giving me the opportunity to achieve that.

One thing I did test which seemed to help was turning off "Test Normals".  It looks like this helped on sharp convex creases (back of ears, edges of eyes), exactly where the normals dot test would be screening out vertices.  Unfortunately it didn't help with the area above the eyelid.

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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.