You know that visual bug with Orientation constraints on bones attached to controller objects? Even if you attempt local/world offset on/off, opening the file the bones pivot has been oriented differently. (Say the bones pivot is at an 15 degree angle, it pops it to 0)
Is there a way around this other than having an animation or reset transforms every time you open the file? Its a bit of a pain to open a different layer to select all controllers just to reset the transforms so the bones pop into place.
Assuming fixed on newer version (still using 2012), but would prefer if there is some workaround for this version?
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I'm sure I'd remember something that awkward to get around
Monster will get you one tom. Might not be an issue on later versions.
I noticed you said you were using Max 2012. Do you have the latest service pack? For me 2012 was one of the most broken versions of 3ds Max ever released. As evidenced by 12 service pack releases: http://knowledge.autodesk.com/support/3ds-max/downloads/caas/downloads/content/autodesk-3ds-max-2012-product-update-12.html
It's a good excuse to upgrade if you can. Maybe download the trial of 2015 and see if it works?
I think they fixed that in 2013 or 2014. We went from 2012 where it was happening on a few custom rigs I had experimented with, but when we jumped up to 2014 it didn't happen when I recreated the same setup. I wish I still had the files so I could test them out in 2014 and see if it was something specific with the file. I also upgraded machines in that time so a lot changed.