Sorry to ask guys but i've searched and searched and can't work out what the problem is. It's probably quite simple to you lot but I'm still figuring all this stuff out.
I have successfully managed to complete the high to low poly workflow using 3dsMax, Zbrush and Xnormal before however this time I have some errors in my normals bakes. I have tried creating custom cages in max, I have tried using the built in Xnormal one and have exported over and over to try and get the correct settings but i'm obviously still missing something. If anyone could help i'd be very grateful.
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I shall take a look at textools @Gazu thanks.
Here's the low poly wireframe:
@Jaston3D Hey man, I've been exporting as an .obj - I shall have a look for the split per vertex thing you suggest anyway. I can also take a screenshot of the export settings for .obj if that helps?
other thing to keep in mind. If this model was imported from another software, You should always put EditPoly or Edit Normals modifier to reset vertex normals information, because it's always locked after import.
Hey again @armians. Yeah I removed all the smoothing group information as someone else suggested trying this. Should I go about re-applying the smoothing back to how it was in the first place?
Also when i open the same file in my 3dsMax it doesn't look the way it does for you.
These were the settings I exported it out with. The main thing I can see different to yours is the optimize section. Could that be the cause maybe?
anyway, here it goes again:
"Optimize" does brake things, You should turn it off.
If You removed all the smoothing groups information, this means that now every poly has it's own smoothing group, which means now You have to split all the edges in Your UVs.. I don't think You'd want that x]
Like GAZU mentioned, You should split Your smoothing groups according to UV splits. It should then look like this (green edges are hard edges, just like Your UV borders):
Keep in mind though! If You do this, You Must bake with cage in Xnormal! x]
[Edit: Applying the edit normals modifier has fixed that]