I am relatively new to zbrush, but have been able to make some kinda cool stuff. The easiest way to get the look i want often times turns out to be just adding new polys using Insert(shape) brushes and then placing and modifying the shape. An example of this is in making a forced perspective diorama of a cornfield. To make the corn, i just did InsertCylinder, placed it, then shaped it to like like a corn stalk, then duplicated it and rotated it until I had subTools of dozens of corn stalks, getting smaller and smaller as they go further back to the vanishing point. It made for a cool effect. (I know I could have done a half cylinder insert and dynameshed and it would probably have blended it into one mesh, but that would also have killed some of the detail and made it a lot harder to quickly place about 1000 corn stalks.)
The problem comes when I want to have something done this way SLA 3d printed. My understanding is that in order to print properly it needs to be one unified mesh with no overlapping or internal mesh. Normally to fix this I merge everything into one subTool and hit Remesh - RemeshAll at the highest resolution with the symmetry turned off. It makes a new unified mesh subtool, deleting all of the internal geometry, then I simply project the detail of the original subtool onto the new one and I have a pretty good looking printable model. Not quite as high detail as the original was, but good enough for what I’m doing.
With these corn stalks however, I have an issue where the corn gets bunched together pretty tightly as the perspective shrinks. This means that when I remesh the corn, the back rows wind up looking like a rectangular blob instead of individual rows and no amount of adjusting the sliders will project the detail of the old subtool properly.
So basically I am not sure how to fix what I am doing. Is there a better way to get a unified mesh? Or is there an easier way to delete internal mesh?