ok, so I understand the concept of normal mapping and when it comes to organic objects my normal maps all seem to work very well. This all changes, however, when I try to create a normal map for a hard surface, especially things that have to have straight edges (pieces of a robot, binoculars, gun barrels etc.) all my straight edges come out warped and the normal map looks like garbage. I feel like modeling straight edges in Mudbox or Zbrush is an exercise in futility so I tried modeling both the high and low resolution models in Maya. This is when I get the most warping in my Maps. Is there any way to get out of this pit of hard surface frustration?
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I know my explanation ain't good but it's hard to describe.
http://wiki.polycount.net/Normal_Map#SmoothingGroupsAndHardEdges