Are there known examples of actual casts, as opposed to carved images, as here?
I am not aware of any such tradition. In general, ancient Egyptian art has an idealizing goal. Therefore, a cast of someone's face would not be necessary for a "perfect" depiction of the individual.
That said, you can see different trends in idealized faces across time. The head of Hatshepsut that you sent has some distinctive facial features that can easily be contrasted with nearby images of Middle Kingdom kings, like Senwosret III, for example.
Thank you! I would assume that casts would be of dead...
You're welcome! I see what you mean. While the "death mask" is a tradition in other cultures, it was not a part of the Egyptian mummification process (or rather, pre-mummification ritual). Preparation for the afterlife is a time when idealization would be especially important! Interestingly, there is a plaster mask that was sculpted onto a wrapped mummy, it's on view in the Mummy Chamber. It was not cast directly from the person's face and the practice fell out of fashion.