You can control which materials get outlines using the toonID setting on the materials settings. As an example, for Jessie with the seperate head and body materials, normally a line appears across the neck. If you set the head and body to have the same ID, no line.

Certainly helps around the eyes etc. It also means you can create extra outlines using the grouping tool - create a new group that contains the area you want outlined, assign a new material. Copy across the original material, but change the ID. When you render, your new patch is now outlined - good for enhancing the lips for instance.

One option for anti-aliasing - make all the materials invisible, then render with the outline on - all you get is the outline, which you can then blur in another package and merge with the unoutlined version.

A wacro to do this will follow - works OK, but fails if transmaps are used - I'll fix it then post it.