Hi Pat,
That is a good question
and luckily it has a good answer and even better, it comes with an easy solution…
Why is this edge visible?
All of ZBrush default objects can be created by mathematically ‘folding’ a flat surface in order to get the desired shape. The line that you are seeing is where one side of this surface meets the other side (it is clearly visible when using DOTS mode and especially with a Ring3D object). There are 2 common methods that are used when exporting such mesh, one method allow the mesh to be exported as-is in which case I have found that some applications will not handle the edge-line properly and you’ll get undesirable texture distortions near the edge line. The other method requires that the vertices of the edge-line will be exported as double points, one point with UV coordinates on one side of the texture map and one more point with UV coordinates on the other end of the texture map. This method does not suffer from the texture-distortion problem but it may, in some applications, produce a sharp edge.
What to do?
ZBrush can handle both methods and by default, the ‘double edge’ method is used when exporting a 3D mesh. If you want to have the double edge removed, you need to do the following…
- Select the PolyMesh3D tool (Star shaped tool) and set the TOOL
INVENTORY
IMPORT
Weld value to be larger then zero (0.001 would do just fine)
- Import the OBJ file.
- Export the OBJ file
That’s all; the above procedure will remove any double vertices that are sharing the same position in 3D space (you can use the procedure on any 3D mesh, including those that have not been originated in ZBrush). When importing an OBJ mesh into ZBrush, the mesh is automatically analyzed in order to find these ‘special interest’ vertices and when in DOTS mode, ZBrush will draw these vertices in green. When importing a mesh with Weld value set to 0.001, you can turn the DOTS mode on and you’ll see that the object no longer has the double-edge and green line has vanished.
I hope this helps 
-Pixolator
P.S. I am currently unable to reply to questions as promptly as I would have liked
but this will no longer be the case after 1.23 is released :)(we are currently finalizing the release version and hope to have it downloadable by Monday or Tuesday night.)
When 1.23 is available, you can use the script below to automate this process… (or simply record it inside ZBrush once, and save it. )
:large_orange_diamond: :large_orange_diamond: :large_orange_diamond: ZSCRIPT BELOW :large_orange_diamond: :large_orange_diamond: :large_orange_diamond:
[IButton,”Remove Edge”,"This function removes the visible edge from an imported 3D object”,
[IPress,TOOL:PolyMesh3D]
[ISet,TOOL:INVENTORY:WELD,0.001]
[IPress,TOOL:INVENTORY:IMPORT]
[IPress,TOOL:INVENTORY:EXPORT]]
:large_orange_diamond: :large_orange_diamond: :large_orange_diamond: ZSCRIPT ABOVE :large_orange_diamond: :large_orange_diamond: :large_orange_diamond: