welcome Mark.
Are you looking at doing your singing faces with Old school dumb strings (like me) or are looking at smart pixels?
Synchronising either takes a bit of time, but I believe it's easier in X-lights if you have the lyrics. (I'm LOR S4 and S5 supposedly makes it easier)
Plenty of people here to help share the knowledge. Heaps and heaps of video's on YouTube
First post I see from you; sorry that your notifications are filled from being tagged in the chat. Occasionally someone tags @Mark rather than @Mark_M .
Anyway, good to start somewhere!
Show us how you plan to make these and members will jump in with some tips.
I have made my own props with corflute before. It costs less and is more fun than buying it pre-cut!
Made from 5mm corflute and 25mm conduit from Bunnings. Holes were punched by a hot circle punch, this melted the edges which helped with rigidity. This was made to align 12v regulated Ray Wu icicles to a grid for text and other effects.