This doesn’t work for me either using “Export Model” head routine. The modified head fails to load back every time despite the fact I only move polygons not change the number. I use the old software Argile2, once promoted by RL, for this.
However......Something similar which does work for me is:-
Load character in Iclone. E.g Chuck
Click edit in 3dx
In 3DX select RL_FACE and export that mesh via the “Replace Mesh Panel”.
Modify mesh and save as .obj (again I use Argile 2 for this).
This .obj file I can successfully and reliably bring back in 3DX with Import Model button in “Head Morph panel”.
Option to export/save as Head.vns now becomes available.
Back in Iclone I can use the Head/Face/Custom panel to navigate to the location of saved Head.vns and apply the morphed characteristics to the head of any currently selected avatar of same generation.
Found this some time ago by trial and error after becoming so frustrated with failure of documented method.
Maybe it will work for you JC W ?
Geoff.