I just read that FAQ and note one reason crew isn't really planned is due to having to make so many models.
You wouldn't have to.
There are wonderful procedural systems where you use a single simple human model, plus procedurally driven alterations to the various aspects of human anatomy. Once procedurally generated, you would only have to store the settings that were used to generate that look.
As to animations ..
Non-linear animation.
A pool of short animations that are semi-randomly blended together and between depending on the station.
Just a couple thoughts. I've been doing 3D stuff for nigh on 25 yrs now. I don't do much character stuff, but I do use the tools sometimes. Primarily in Blender, using Manuel Bastion's MBLab or MakeHuman. Poser would be the commercial software version, but I'm not so sure it's worth the cost.
At any rate, perhaps these are things you hadn't considered. Very cool project.
