I think it's just a case of bad sculptors combined with deadlines. Somebody designs a dud and by the time protos come back, it's too late to start over. The molds are probably already in production and they're merely worried about plastic colors.
In my brain, all the bad Classified headsculpts are by the same dude... who they will hopefully reassign to the mailroom after Covergirl, Falcon, and a few others. It shouldn't be a secret internally whose work is routinely despised by consumers. We're nothing if not a vocal fandom.