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I've never tried this but it seems like you should be able to create multiple heads for the same body and and export them as separte mesh files with separate material files. The only limitation I see is that the mesh files might have to have the same structure (ie same number of polygons and polygon order). I'm not sure how this will affect animations, but if the mesh files have the same structure then I don't see any reason why the old animations wouldn't work.
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