My favorite Living Character, although not a product of the initiative, is Colonel Suchbench, late of the Adventurer's Club. Best incarnation of a living character yet.
I think I heard that the Stitch to be used in Tomorrowland once the stage gets completed will be LCI as well. Is that correct?
And I Potato Head usually talks from pre-recorded lines, but I've heard some stuff that I was pretty sure was live -- he asked "the little girl in the orange shirt" if she had been on the ride before. Either he was live or they recorded some random combinations of boy/girl shirt color.