I've fallen behind in my updates here. I've finally got all the parts sized the way I want and they are off to the printer. With any luck, I'll have them and send them of to be cast within the next couple weeks.
Here's some pics:
There will be enough for 10 figures, 2 options for a Sgt., and 2 extra weapons. The xtra weapons are a grenade launcher and a flamethrower. There will be 15 heads, 5 each of the 3 variants.
Like any new process, this has been a real learning experience and future sets should go much smoother.