Sculpting software import into Fusion 360

[dangartland]

Hello,

Is there a recommended sculpting software comparable to ZBrush from which high resolution models can be successfully imported into Fusion 360?

We need organic surface modelling and the ability to apply surface texture onto models, which would be used in making moulds, rapid prototyping and other manufacturing processes.

We tried importing our model into Zbrush to apply the texture but we have been unsuccessful in importing back into Fusion. We can only get mesh models into Fusion which we can not covert into a BRep due to facet count. When we remesh the model to try and reach the 10,000 facet limit the detailed texture is lost.

To understand our requirements, we have a model with 250,000 facets.

Many thanks,

Dan

[jodom4]

Hey dangartland,

I'm not aware of any particular sculpting software that has better compatibility with Fusion than Zbrush or any other sculpting software. Hopefully someone else in the community will have more insight on that.

Here's a video I just made on a workflow from tri-mesh to BRep that might be useful. The level of quality to be sacrificed depends entirely on the model you're using, of course, but you might be able to get there using this method.

https://youtu.be/SnPkl-3H9Ws

At this point, the best way to get a mesh into Fusion as usable geometry is to rebuild it. We've got some tools that will help with that endeavor, but if you're working with something that's been sculpted with complex surface textures, Fusion might not be the best option. See the screencast below for that workflow.

We currently have an internal tool for converting tri-meshes to quad meshes in development, but it's not open to the public yet. Keep an eye on the Blog for releases on that topic.

[dangartland]

Hello Jonathan,

Thank you for your response, I will try your Try-mesh to BRep video and see how well that can work for my use.

The level of detail has to be done in sculpting software like Zbrush due to the complex surface texture required. I unfortunately can not find the screencast you commented on about Fusion 360 workflow, or were you meaning the video link you made about conversion?

I would be very interested in that conversion tool, so I will keep my eye on the blog.

Many thanks for your help,

Dan

[TrippyLighting]

I am not entirely sure what your workflow is but I assume you are exporting a model from Fusion 360 as a high res .stl , which obviously results in a dense triangulated mesh. You might wan to change the relatively large aspect ratio to something smaller for better sculpting results in ZBrush.

Th next assumption is that you apply the high fidelity detail to that triangulated mesh in ZBrush using the sculpting tools. This will likely result in an even higher resolution triangulated mesh.

So far so good. The usual workflow s to then re-mesh that dense triangulated mesh to arrive at a lower poly count quad mesh that is still retaining all the sculpted features.

Once you have a quad mesh as a .obj you can try to import that into Fusion 360 ( turn off auto triangulation in the preferences). That mesh you might be able to convert into a T-Spline. Whether that works is really a question of how the surface is structures and how many quad polygons you have in the mesh.

If it does work, the T-Spline will accurately reflect the re-meshed detail you sculpted in ZBrush, with the difference that it now can be converted into a BRep and then precision machined.

Converting it to a BRep directly from a mesh willingly work if you reduce the mesh loosing all the finely crafted sculpted details. then of course the BRep will also not be smooth, but faceted. For low end 3D prints that might be OK but unlike;y for a precision machined mold.

If the quad polygon count is too high for Fusion 360 there are at least a couple of other non AD software options available, albeit at a higher price. 

Cyborg 3D makes a Sub-D quad mesh converter that comes standalone or also as a direct t plugin for MoDo. It is the same engine the powers the Power Surfacing in Solid Works.

Solid Thinking Evolve has poly nurbs and in my tests abut a year ago importing and converting a complex quad mesh  into a NURBS surface was 17 times faster than a T-Splines conversion in Fusion 360. But is is definitely not a cheap option!

[dangartland]

Hello,

I have tried your tutorial with a relative amount of success. I was able to convert my model into a quad mesh (using MeshLab) and then import into Fusion. It allows me to start the conversion into a t-spline but my computer ground to a halt, using all of the available RAM on board to the point where I have to force quit.

I believe this could be the way to import the model into Fusion but there seems to be either a hardware limitation or just the level of detail that Fusion can not physically handle.

My specs are:

iMac (Retina 4K, 21.5-inch, 2017)

Processor: 3.6 GHz Intel Core i7

Memory: 16GB 2400 MHz DDR4

Graphics: Radeon Pro 560 4096 MB

What do you think would be the facet limit that Fusion could actually handle?

Am I reaching the absolute limit that Fusion can reach? Or could this be due to my computer limitations. I feel that my computer specs are fine for Fusion, so I think it is Fusion itself that just can't handle this.

For @TrippyLighting,

Thank you for your response, I initially start with an obj file into Zbrush, but the rest of your assumptions are correct. Your processes specified have helped me to understand how Fusion works and what I can do with it.

Your recommendations on other programs are brilliant, thank you for telling me about these options.

[TrippyLighting]

---

@dangartland wrote:

I believe this could be the way to import the model into Fusion but there seems to be either a hardware limitation or just the level of detail that Fusion can not physically handle.

My specs are:

iMac (Retina 4K, 21.5-inch, 2017)

Processor: 3.6 GHz Intel Core i7

Memory: 16GB 2400 MHz DDR4

Graphics: Radeon Pro 560 4096 MB

What do you think would be the facet limit that Fusion could actually handle?

Am I reaching the absolute limit that Fusion can reach? 

---

What is the quad polygon count on your meshes ?

[dangartland]

The only file I could export out of MeshLab was the full resolution model, just converted into a quad mesh.

Vertices: 372,281

Faces: 744,558

I tried reducing the vertices to as low as 25,000 faces, but MeshLab could not export the file because it would freeze due to the amount of RAM it was requiring.

[TrippyLighting]

There's no way that Fusion 360 can handle that amount of faces. I am not even sure any of the other products can.

Maybe time to think about manually re-topologizing the mesh using Topogun or another retool tool.

Can you post a image of one of those meshes ?

[dangartland]

Okay, at least I know I am just pushing the software too far.

The Tri Mesh was built to have small triangles in highly detailed areas, but bigger triangles in low areas. You can see this in effect in the picture. Maybe there is just too much detail to properly transfer this type of model regardless.

The effect is to make the model look hand made out of clay or of a similar material, so that when a mould is made of the model they all look hand made. This is why I needed this amount of detail. It is hard to see the effect in this picture but at least you can see the mesh.

This is only part of the model, the part is bigger than what is shown.