Not sure if you've finished taking suggestions, but I have a couple more.
Primary use: Search and Rescue (intermittent on/off to check maps / navigate, permanent flood use for tricky terrain - spot/throw for use in tight indoor areas, but mainly will be provided by handheld flashlight)
Secondary use: Mountain / road biking and touring (in addition to a handlebar mounted light).
Power source: AA (easiest to get hold of, cheapest to run rechargable). I don't fancy explosive lithium cells fixed to my head.
Switch arrangement:
Switches must be operable whilst wearing gloves. I don't want to dazzle myself or my team, so definitely no instant death-beam.
I know it's very non traditional, but I'd prefer an analogue rotating power switch for each LED, so I can set the brightness to a specific level. This probably compicates the electronics, and certainly makes it more challenging to waterproof. Either way, I wouldn't want it to go into high mode when initially turned on.
Other thoughts:
Make sure the weight balance is sensible for the strap elastic - I don't want it wobbling around when I move, I don't want to have to make it so tight that my brains start coming out of my ears just to support the weight, and I don't want to feel like I'm carrying bricks on my head.
It has to be waterproof (preferably submergable, not just splash/showerproof)
Also make sure there are minimal sticking out parts that can catch on branches. Ensure that any wires to battery packs are clipped / secured to straps where possible, I don't want to end up hanging from a tree.
Just a few thoughts...