I'm not sure exactly whether this fits here, but as it's a concept currently in development, this seems like a good place to start.
There's been a lot of work done on singing skulls, and some have made some animated face displays using rope lights, but I've been messing around with the idea of a single circuit board that has various circuits and each circuit has its own set of LEDs. The circuits outline various facial features and in combinations could create some pleasing (hopefully) effects. The most current idea would use a 24-channel controller for the face. Believe it or not, this idea comes from a recent viewing of an old movie named "Futureworld" which included several scenes where the "face" of a robot was removed from the head. Therefore, I'm calling this "FaceBoard." (Now just watch, I'll get sued by the Facebook guru... :lol:)
Below are some sample pictures of how it might work. I'm still refining the idea, but my current thinking is that a single 8"x10" board could be laid out with LEDs to accomplish this. I haven't gone past the basic idea yet into the electrical calculations nor numbers of LEDs required, but the idea here is that the front of the board would have the LEDs while the back-side of the board would be the controller. It could be wireless (of course!) but the idea is that the the FaceBoard could be stand alone and could be easy to add to an existing wire frame or other display, possibly even a blow-mold.
Anyway, here are some drawings I worked up so far... The first picture shows all the facial elements (24 channels) while the others show adaptations of how it might be used. Comments?