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I used to use ping pong balls as registration spheres. I noticed as I was scanning that some scans were aligning very well but the spheres that were usually at the periphery of the scan envelope were not. I concluded that it was an indication that, as you get away from the "sweet spot" of the center of the scan envelope, the factors that cause errors in the scan become more of an influence (lens distortion, focus, Calibration quality, projector issues etc.) If you don't need a lot of surface detail, and are using HD hardware, try moving your rig further away from the subject (you can even calibrate to a slightly larger cal standard). A common mistake is the desire to get the camera and projector as close to the subject as possible to capture as much detail as possible when geometric accuracy is really the most important parameter.