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