Studiospares do a little mixer called the QMix which has a stereo in plus 4/6 Aux in's (I can't remember the details). It is reasonably priced at £250'ish. It will drive 6 pairs of headphones with their own individual mixes. I am planning on getting one and connecting it to the 8 bus outs on my mixer. I record in a similar way to you with direct outs going to my DAW so it matters not if channels are assigned to buses.

The Oz Audio Qmix is great if that is what you are talking about. I do believe they discontinued them (at least on musician's friend's website)

There is a couple places still selling them online. You can keep it in the tracking room, and let the band make the adjustments. Works quite smooth.

http://www.macmidimusic.com/prod.itml/icOid/2514

your headphone amp has auxilary input on the front....

just run four more cables to it with the individual signals of those who more of themselves and mix that with the stereo headphone mix....

there is a good chance people want more of themselves.... :lol:

I also had to get creative on a soundcraft ghost when i was tracking through it. because the foldback section is only aux1&2.I split the direct outs at a patch bay and injected whichever channel i wanted to the aux in on the samson s phone amp channel, which allows it to be mixed in with the foldback and boosted or cut without effecting whats going to tape. check your block diagrams on your console and your headphone amp and just experiment.

a furman hd6 will send 4 mono tracks and a sterio mix to up to eight HR6 units that will give each band member to dial in there own mix

http://www.proaudiosuperstore.com/furman-hds-6.html