I'd appreciate help with this, too.
I have read (and verified) that by selecting an existing actor in the Object Window then pressing ctrl+F4, the face can be exported as a .nif file to Data\Meshes\actors\character\FaceGenData\FaceGeom\Skyrim.esm.
However, I'm not clear how to import that file to a new actor, since the import button is expecting a .npc file.
I tried changing the id of the .nif file to the new actor, but that didn't work, either in the CK or in game.