Hi there, I’m a digital sculptor and designer at Weta Workshop. Most of my involvement on The Hobbit was in the Collectible line released. I have sculpted several of the Dwarves as well as Azog on the Warg for the Weta Hobbit Collectibles range using Z-brush.
It was an interesting process to navigate, and it evolved as we sculpted more figures in the range. After a piece had been fully sculpted, we then cut the figure into pieces and inserted a peg and hole so that when the pieces were 3D printed, they would be ready to fit together snugly. I’ve attached a couple of pics of that process as well as the finished Z-brush pieces. After they’re 3D printed, we moulded and cast the pieces in hard plasticine and sculptors cut some of the detail back in that was lost in the printing process. 3D printing is getting better and better to where we’re no longer having to do this part of the process, and can take the 3D print directly into paint, which is awesome!
Here’ is a link to the Weta Website where you can see the finished, painted collectibles:
http://www.wetanz.com/hobbit-auj/
Cheers guys, I hope you enjoy!