Currently looks like the highpoly uses support loops plus subd which will round off the edges. Adding an actual bevel might help here. One could also map UVs to trims. Here is a test to illustrate what I mean.
Yes, you are right, it was done with a knife tool. I didn't care much about topology, for sure it can be done better. It's just to illustrate how adding control loops can tighten up geometry when used with a subdivision surface modifier.
No, you were letting the loop go down the entire length, run it off into another vert right outside the box, end it early so it doesn't run all the way down. you want it to merge into the edges that are existing defining the cylindrical shape.
Well, im new to subd so I still got a lot of practice (i.e. iteration) until I get good at it, but I was hoping there would be a better way to manage edge loops. Thanks for the workflow link, those are some great tips.
I figured a way round about way of doing it. Rotated the face 45 degrees. Then had an edge loop a bit back, which I flattened(snapped) the vertices, forward, straight along the edges(non distorted edges), towards the rotated ones.
Swiftloop does exactly that and is built into Max since 2010 or so. edit: I'm a liar, Swiftloop does better than that - there is no need to select an edge to build the new loop off of, it autodetects which edge you're near and can change that in real-time.
As far as i remember straighten loop takes the endpoints(verts) and creates straight line with the verts inbetween. For easy shapes like that you could also use Slice Plane, place it how you want it, click slice and delete the unwanted part.
You can just add 2 edges when chamfering instead of 1, but it will still slightly smooth the middle loop, so you lose a bit of volume compared to solid chamfering, but it's similar enough. Would be a nice addition to the chamfer options though.
also dragging our spline around hte curve of the geo, and using it as a snapping point, when adding additional edge loops works great too. really easy in maya, just constrain to one axis ,and hold C and drag it onto the curve.
@abronee I think you are over thinking this pretty hard... Just think of how it's constructed and break it up into those pieces, it's literally blocks on blocks. Do a blockout of the model before thinking of adding loops and stuff, it will make things much easier.