At work we do plastic injected objects, like for example plates, rings, most are promotional stuff.
Latley we´ve been investigating in the making of character toys, like for example a superman toy. I´m not interested in rapid prototyping, since we would be making from 200.000 to 2.000.000.
I´m doing the base in Rhino and then trying to sculpt it in Zbrush (had some trouble in the passing from one program to another) and then need to export it back to rhino to adjust it and make it a solid mesh object to then make the to parts of the mold to be machined in the CNC on to a block of metal.
You could look at Rhino CAM to program you Tool path it will take mesh files. So you would be able to generate TP from your ZBrush files. If your on a 32 bit Windows system your limited to 1.5 million polys max. I usually try and keep the polycount to under 800,000 to avoid running out of memory when generating tool path.
Ive been doing my work for many years using Rhino, Zbrush, Lighwave, Modo etc I then CNC all parts and sculpts in toy sculpting wax. I also send some stuff out for RP. Are you guys tooling from an physical part? OR are you looking to go right from CAD or Mesh to tooling??
www.bntstudios.com to see my work.
But I need to make the mould from what I’m exporting from ZBrush, and in rhino I can’t work it to make the two parts. I made a prototype in the machine of the toy, but what I need now is to make the molds, so I can make the toys in plastic.
What I import in rhino from ZBrush, I can’t make operations as booleans. That is what I need to make the two parts of the mold.
Here I upload an image of the prototype made in aluminium.
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