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Extracting Normals - High Poly Hard surface

Hi,
I’m currently trying to figure out the workflow for creating game normal maps for hard surface objects. I’ve build a low poly mesh and a high poly mesh. The high poly mesh is built up of many different pieces that simply intersect and I can’t seem to figure out how to get a decent normal map by using the transfer maps tool.



So what I have been doing is taking the high poly mesh that has multiple objects like boards and rivets and just combining them into one mesh. Then I place the high poly over the low poly and attempt to use an envelope to bake the normal map out. My low poly is UVed.
Every time I try this I get the same results over and over again, resulting in a pretty ugly normal map.



Does the transfer maps tool only work if all the high poly objects are merged together seamlessly?? meaning that I can’t just take an object and translate it into another object and combine it? If so, is there another workflow to achieve this?



I attached some screen grabs for some more information....



normalmapscreen.jpg



Thanks
-Cody

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