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While less fancy, I'd just assign the head to a companion, either via KSE, editing appearance.2da or creating a disguise item, and go through conversation options with them. Generally when something is wrong with your weights it's quickly noticeable. Granted, you won't really get any extreme animations to test your skinning, but player heads rarely move much anyway.

The game doesn't have any dedicated facial animations aside from the mouth flapping for VO phonemes. Anything else is part of a larger animation for talking or listening. You can try creating a DLG and specifying various conversation anims like TALK_NORMAL and so forth. Otherwise, in TSL you can script any anim in the game (in K1 you can only script a limited selection listed in nwscript.nss).

Faces have the following structure: vertex_index1 vertex_index2 vertex_index3 smooth_group uv_index1 uv_index2 uv_index3 material The last value, i.e. the material, does indeed get lost unless the model node is a walkmesh. This is the behaviour of original KotorBlender and I don't think it's necessarily wrong. Exported area models seem to work ok regardless of the lost information.

Thanks for the feedback. I've fixed the first two issues you've found. Regarding alpha: where are you expecting it to be set? Currently alpha is written to and read from the Multiply shader node (the second input).

Nice to see it updated. Just three things. First: Blender 2.80+ makes meshes double-sided by default. So the code to turn the lightsaber blades double-sided is redundant and results in a trace back error when imported. Second: I imported a character model and exported. Some of the tangentspaces read as tangentspace false instead of tangentspace 0. This lead to a mdledit error. Changing all instances of tangentspace false to tangentspace 0 let the model go through and everything worked as intended. Third: Unsure if the next one is a bug or user error, but I had some trouble getting any alpha other than 1.0 to export.