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The new one piece silicone face, ears and neck part is nearly done. It's complex and making a mould for it is going to be a mind bender. 
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The mould for the scalp is done.  It's a three part mould that will produce the silicone piece that looks like this (image below) and covers the top of the skull.  Producing this mould on my ender 3 will take at least 3 days... maybe 4. Time to fire up the printer!
The new design of Aleyshas back of the skull has finished printing. Magnets are glued in and it's spray painted. Super happy it actually fits to the skull face perfectly and screws into place with M5 screws just as planned.  Here is another view with the face detached.  Next will be the silicone scalp. For that I'll need to make another mould.
First of all I am going to attempt to cast the face, ears and neck as one piece for the next iteration... which means making a massive, complex mould... this will be a challenge. Second I have decided to remove the borders between silicone parts. The seams will be visible, but the overall surface won't be interrupted by hard plastic. Third the neck vertebra were trickier than anticipated! After 2 failed designs I believe I have arrived at a design that will be able to support the weight of Aleysha's head and at the same time allow for smooth deformation of the neck instead of just... folding over. Only a full scale test will tell. I'll also need a strong core to thread through it. Going to try steel wire. The aluminum was too soft.  On a side note the cyberdoll.co domain seems to have stopped forwarding to this one... but I don't have time right now to look into it so I'll just continue with mattslog.com for now.
Think I arrived at a design that could work. Whether or not the magnet placement works well remains to be seen. The idea is to have a hard border between the silicone patch of the face (which will need to be redesigned to include the ears and neck) and the scalp. Time for a test print to see if this piece attaches well to the skull face.  Starting to think about the back of the skull and how it's all going to be put together...  On version nr.3 for the face mould and skull face now. Think this will do for now. The skin deforms well when the mouth opens and stays in place around the eyes.  This is what the latest version of the face mould looks like.  And here is the skull with teeth and eyes inserted and the separate skin.  The same thing from the back again. The encapsulated magnets have fused well with the skin and make it plop right onto the skull.  Since the next version of Aleysha has slightly bigger teeth, new teeth moulds are needed. These turned out much cleaner than the first batch and they only have 2 parts instead of 3. So less seams! :)  Magnets are glued and the new skull is primed for spray painting. Just gotta wait for the color to arrive.  The design and print of the new skull is now complete.  This skull will keep the skin in place around the eyes when the mouth is open and allow for thicker skin.
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