Zbrush, trouble with merging subtools for 3D printing

cactiwrap

Hello,
I have a model that consists of multiple subtools. At the moment I'm preparing the model for 3D printing but I run into some problems.

The model:

When I merge the subtools and use dynamesh with a resolution of 512 the front part gets cut off. Is it too tough for the computer?:

Another thing I tried was merging it one subtool at a time. I managed, but the jacket Zremeshes in an ugly way.

Before:

When dynameshed and Zremeshed the edge becomes 'folded':

Does anyone know a good workflow to combining these subtools to a watertight mesh while keeping the resolution/edges? I've tried some things, but now I'm stumped. Especially the jacket part bothers me.

phixel

I've been preparing a model as well for 3d printing recently. I've found when trying to merge subtools, merging them one at a time works best. In my case, I modeled my character in 3ds max, and am using zbrush to combine meshes, pose it, cut it into multiple parts and add keys (like separating the arms and legs from the torso so as not to have to print with as many supports, this will hopefully increases print quality). I first duplicate the subtools i want to merge, perform dynamesh to merge them, and then use the originals to run a project to get back any lost detail. Then I can zremesh, to reduce polycount, add a couple subdivision levels to smooth out the surface of the model and use the project function again as needed to maintain detail. With the zremeshed merged subtools i then posed my character, and am now in the process of cutting it apart to add keys.