The Character Sketcher  
   You don't have to be an artist! Draw character and NPC portraits in seconds! Mix and match pre-drawn facial features to sketch out a composite portrait of your favorite character.
   http://www.nbos.com/products/sketcher/sketcher.htm

Hero Machine  
   Build a character online. Using Macromedia's Flash program, the HeroMachine lets you control all visual aspects of your character, from capes and boots to faces and weapons.
   http://www.heromachine.com

PCGen  
   An open source java based character generator and maintenance program aimed at supporting all d20 system.
   http://pcgen.sourceforge.net/

Random Fantasy NPC Generator  
   Although designed to create Non-Player Characters for RPG's, this software can assist in creating personalities, particularly for worldbuilding histories.
   http://spitfire.ausys.se/johan/npcmaker/default.stm

Command Line Character Manager  
   An open source program developed to assist users in generating character sheets for their characters. Includes HTML output for uploading files to the web.
   http://sourceforge.net/projects/cl-charman