what are the main ground rules here. I am doing a job for a toy company and the model is actually being manufactured, so its a not a 1 off 3d print.
I guess you make everything shells and try and build most things as 1 mesh ie if you have buttons on a tunic they would be built in?
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But yea, I guess you will be 3d printing your model as a presentation piece? Or maybe to be used as a blank to create molds for production?
-I would say make sure each piece is a closed volume. Include secondary parts like buttons, straps or surface texture as part of its larger associated piece (for example: pants and a belt).
-Avoid undercuts as much as possible for simpler molds.
-For mechanical type pieces, have decent draft angles (not 90 degree walls) to allow for the pieces being produced to come out of the molds more easily.
-Include bevels on sharp edges & corners.
-Think about how the molds would close around each piece as you're modeling your parts.