From what I read, the names of characters in books are not copyrighted. The author can copyright the name though. This is the case with the name "James Bond", from what I can figure out. But from what I can figure out, this is very rare, so you should, theoretically be able to use the exact names, although I would do my own research to make sure if I was you. As for "Aragorn is a dead ringer of the actor Viggo", there is no way you could get away with it.The actor could sue you, the film company could, and even the clothes designer could. That does not mean that they will, but they could. But if you read Lord of the Rings, and based the character on your own imagination, then there is no way that he would end up looking like Viggo. And that is what is important. You must have some element of design, or some feature, that clearly makes this creation your own, and not a copy of someone elses representation of the same character. If you look at Orca Designs ORC CLAN WARS package, those Orcs do not look like the film versions. This makes what he has done perfectly legal and acceptable.

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