Is it really necessary to have UVs in the hi res mesh? The reason I ask is that my low res cage does have UVs on them but I didn't bother to update my hi res mesh in Zbrush with the new low res topology. Yes I know about importing your new retopologize mesh into Zbrush and transfering all the details but is this a necessary step?
I tried generating a normal map in Xnormal with my low res mesh that had UVs and my hi res mesh without UVs. Somehow I got some of the details from my high poly sculpt transferred over to my normal map but not as crisp as I want it to be. Am I doing this all wrong by skipping a step?
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Only LP must have UVs.
To get more crisp results from Normal Map try to encrease the map resolution.
For example you might be working on a statue and you applied a stone texture to your high poly, it can be helpful to capture that materials bump/normal and diffuse coloring, it properly accounts for stretching in the UV layout of your low poly and will flow across UV seams where doing that stuff later in photoshop can be tedious and time consuming.
Wood grain is another one that helps to capture from the high poly.
Last night I did some tests in Xnormal on just the shirt transferring details from the non UVed hi res mesh to the UVed hi res mesh and the results were far more better in terms of details being transferred over to the low res mesh. Although I got better results from it I didn't test the low res shirt with the UVs packed with the rest of the other models. Meaning that the resolution on the shirt in terms of ratio is far smaller than before I packed it. I'll try and post some screenshots so you guys can see the results.
-You can unwrap your HP and do a UV-bake, I'm not sure how much more beneficial this is to a standard Cage bake, but it might help with uber-low poly bakes especially if you have the details where you need them to be exactly, without stretching.
-Upsize your bakes to double the original res, if you're baking non-micro detail and downsize to half the size.
-Most people tend to have (usually) 2K textures for the entire gear of a character (clothing, belts, pants, etc), save for reusable assets, like guns for example and pending on game-type, 1 or 2K for the organic parts in total (hand, feet, face, etc).
HOWEVER, the going back to the '2x bake res and downscale' point I made, you need to always make sure the detail you're baking will fit in an original map.
I made the mistake a few times where I baked a full art-nouveau kit for a character on a 2K map, downscaled it and bam, everything looked like a PS1 non-linear filtered texture full of tiny squares on it, so I honestly don't suggest willy-nilly 2:1 baking of textures without knowing before hand if the texture will even look good, especially once you have done all of your painting and maps at the 2:1 size.
So I suggest always baking at 1:1 scale first before a 2:1 process. Ofcourse, XN is pretty fast, so you could always bump up the AA to 2, since the baking time is negligible, 4x will take a little bit longer, but nowhere near as long as it might take you in other apps, and it will give just the same results you would get with a 2:1, even better sometimes.
Lastly, make sure you UV shells are Normalized (EI: meaning they take the same UV shell space as in 3D space size with the other models that will be in the same unwrap, there are a few plugins that allow this) it's important, especially on very low poly models, so you can gauge if something needs more textures space due to it's importance, or you want everything to share the same 'quality' in terms of details on your textures.
I have numbered which shirt was unpacked and packed. Number 1 is the unpacked UVs and number 2 is the packed UVs. Everything looks fine at a distance until I noticed a seam on the left side of the shirt when zoomed in close, on the right side it looks fine and hardly noticeable but on the left there is clearly a line (I'm talking about the packed UV version). The detail on the left side of shirt also seems off where the seams should meet. I'm not going to worry about it as much since it is going to be covered by a vest or some other modular items on top of it.