November 18, 2012 at 11:16 pm
Here is Part One. You should read that first. :-D
Now it is time to separate the face from the head cap. I chose to make a face-plate, since I want to have lots of faces and face-plates are less volume (which means less expensive) and easier to mold. I am not going to show how to make the head cap and all of its inner workings, mainly because that is already done and it would take me a lot of time to redo. So, for right now I am going to keep it simple and just focus on the face.
Step 2 – The Face
Create the Slice Plane
Just like we did before, we are going to make a plane that will define where the face gets cut. This is another thing I reuse, but luckily I didn’t collapse the turbosmooth so you can see what it looks like. This plane is a little more complicated that what we used to slice the neck, since this will define what the inside of the face looks like, where as before we just deleted the cutting plane and all we cared around was where the surfaces intersected. I can’t remember exactly what I did to create it (sorry, it was over a year ago and I don’t think I saved a file for that step) – I know I did some sort of “trick” to make the width consistent, unless I just manually manipulated each vertex until the width looked right ,which isn’t like me but a possibility since I did this so long ago. If not, than I did something fancy will cutting the face, then shelling it inwards, that conforming a low polygon mesh to that. Anyway, the goal here is just to make the inside of the mesh, so do that however you’d like. It should be inside of the face (obviously), and extend outwards outside the head a bit.
Set Up the Eyes
We are almost ready to cut into the face, but fist we want to make sure the eyes have proper holes inside the face-plate. To do this, we will simply extend the holes out by copying the borders a few times, making sure it extends past our slice plane. The hole you are creating should be the proper shape to fit an eye – the hole should get larger as it expands out.
Since I already have the headcap made, I just remove a chunk of it to make it easier to work with. You can still do that if you are making the headcap at the same time, just make sure to copy the head before hand. Slicing is easy to do by just selecting the head element, going down to Edit Geometry, and clicking Slice Plane. Make sure to have Split selected. Then just move the plane to where you want to cut, and remove the back.
I scale out each copied border (just hold shift while scaling with the border selected), then I use the Spherify modifier on the new border to help round out the hole as I go. I also scale the y-axis down more and more for each border so it gets more uniform. You may also have to rotate and move the borders to get it right. Since this face has an open mouth and I am going to use teeth-plates, I am going to do the same with the mouth.
Cut the Face
Now it is time to make the cut! If you are making the headcap as well, you will want to copy the head and the slice plane first. I already have that done, so I don’t have to worry about that. Now, like before, select you head, and crate a ProBoolean compound. I actually use intersection because for some reason subtraction often makes ProBoolean confused for this (I can’t quite figure out why). Otherwise you’d want the normals facing the other direction than they are in the image above. Since we already made the holes for the eyes, the come out nicely when you make the cut. The mouth looks a little creepy, but I will have to go in and cut out the proper shape for the mouth piece later.
If you are making the headcap too, unhide your copied head and slice plane and cut the head like you did the face. You will either have to flip the normals or change the operation. Obviously the head won’t be done with just this one slice (it won’t be hollow), but just create the shapes you need to hollow it out and cut it like the face. It will probably be a bit more complicated than the face, but the idea is the same. Just don’t change the edge that lines up with the face.
Now we have a solid piece that can be printed, but we probably want to add some things to it. I need to add the latch that keeps the face and head connected, and I also like to add the name of the sculpt and my logo to the inside.
Part 3 – Adding Text