Hi Barry, welcome to the RME user forum.

> I am facing some challenges getting my Babyface up and running.

What operating system do you have? Windows, Apple? Which version?

> I've downloaded the RME software but it does not load when I try to open it.

What file(s) did you download? Filename(s) please.
Otherwise, it is impossible to check, if you downloaded the correct files/versions, suitable for your OS.

Basically, there are different types of files, for
- for firmware update
- driver installation, also containing the bundled version of TM FX.

So … if you did not install the driver, then you won't have TotalMix FX.
Driver installation and Firmware update (which needs an installed driver) are also explained in the manual.

If you have Apple, you should look at this page: https://rme-audio.de/rme-macos.html

> I am getting input to Reaper and output to an external monitor speaker but no output to my headphones.
> Is this associated to not having Total Mix opened?

With the BBF Pro, not everything in terms of routing has to be operated in TotalMix FX for that purpose it has buttons and the big dial in the middle (similar to ARC USB, but with fewer buttons/possibilities).

In the well-written manual, you can find information at the very beginning how to easily operate the BBF Pro using those buttons. See chapter 5.1. With the button "OUT" you can toggle between Main Out 1/2, phones, optical outputs.

> On the underside of the Babyface (sort of below the headphone input) there is a tiny hole with the word "void" showing.
> Is this anything I should need to know about?

Look at the opposite / right side, there is a screw at the same position. So … the tiny hole with the word "void" visible on the underside of the Babyface is most likely a tamper-evident seal. If this seal is damaged or removed, it could indicate that the device has been opened or tampered with, which may void the warranty. As long as the seal is intact, there's no need to worry. It’s just there to ensure that the unit hasn’t been opened without authorization.