Real-time cognitive workload monitoring is crucial in safety-critical environments, yet established measures are intrusive, expensive, or lack temporal resolution. We tested whether facial movement dynamics from a standard webcam could provide a low-cost alternative. Seventy-two participants completed a multitasking simulation (OpenMATB) under varied load while facial keypoints were tracked via OpenPose. Linear kinematics (velocity, acceleration, displacement) and recurrence quantification features were extracted. Increasing load altered dynamics across timescales: movement magnitudes rose, temporal organisation fragmented then reorganised into complex patterns, and eye-head coordination weakened. Random forest classifiers trained on pose kinematics outperformed task performance metrics (85% vs. 55% accuracy) but generalised poorly across participants (43% vs. 33% chance). Participant-specific models reached 50% accuracy with minimal calibration (2 minutes per condition), improving continuously to 73% without plateau. Facial movement dynamics sensitively track workload with brief calibration, enabling adaptive interfaces using commodity cameras, though individual differences limit cross-participant generalisation.

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