As an experiment, I tried to make my own 3D printed Lego head using Tinkercad and our Ultimaker 2 3D Printer.
You will need:
Testors Modeling Paint
EZ Digital Caliper (only if you don't use my measurements or want to teach the tool)
Pre-made Lego bodies to test
3D printer
Tinkercad
With the digital caliper, I was able to get precise measurements using a pre-made Lego head and body. You can introduce the students to using a caliper or you can skip this part since the measurements are already done. It wasn't exactly what the caliper measured of course because you have to leave a few .mm as wiggle room.
Here is my project to copy and tinker. The hole inside the orange cylinder is the one that needs to be exact. It is 5.5mm X 5.05mm. All other measurements and shapes can be played with to make huge "Bobble-head" like Lego heads. You can easily delete the hat and ears if you want a standard Lego head or get funkier.
After the meticulousness of painting such a small item as well as the nit-picky measurements, I'd advise middle-high school students for this project. Larger heads might lower the grade level.
The print is made all in one piece with the hat and ears not being removable. I used Testors modeling paint to customize which only required one coat and a sharpie for the facial features.
The print was only 18 minutes, no supports necessary.
You will need:
Testors Modeling Paint
EZ Digital Caliper (only if you don't use my measurements or want to teach the tool)
Pre-made Lego bodies to test
3D printer
Tinkercad
Here is my project to copy and tinker. The hole inside the orange cylinder is the one that needs to be exact. It is 5.5mm X 5.05mm. All other measurements and shapes can be played with to make huge "Bobble-head" like Lego heads. You can easily delete the hat and ears if you want a standard Lego head or get funkier. 
After the meticulousness of painting such a small item as well as the nit-picky measurements, I'd advise middle-high school students for this project. Larger heads might lower the grade level.
The print is made all in one piece with the hat and ears not being removable. I used Testors modeling paint to customize which only required one coat and a sharpie for the facial features.
The print was only 18 minutes, no supports necessary.
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