If a fake Mona Lisa were on ebay, the entire world would call it a tragedy and the person arrested in seconds. Why is it ok to replicate other designs?

You mean like this?
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The book you mentioned at Amazon has been suggested by folks in the past.  Not sure how in depth it is but I believe that any book is worth having.   Light position has been discussed before but not sure at the moment where the thread is. Your ideas for options other then black light puppets are great!  It sounds like the kids would really enjoy them and you could start experimenting with very little upfront cost. I have seen white gloves used before and I think it can be very effective.
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Ahhh... man now I am going to have to get past that learning curve thing and open up Blender.  For some reason I just can't seem to be able to get the hang of 3D yet.  

Great job Andrew!  You seem to always accomplish what I "want" to do. 

Also check out the Puppet Building  or Projects area here at P&S.  There have been some great ideas of recent for workshop puppets.   Patti just did a really cool rod puppet workshop for 80 + 80 + 80 kids all in one day.... I think I have that number right.