If you have no problems with less complex meshes then that would be the problem. If it’s happening with any mesh, it would be a permissions problem that prevents virtual memory from being written. That doesn’t sound like it’s the case, though.
Some things that can get you in trouble:
- A really large undo history. You can delete that or reduce its size.
- Lots of sculpting layers. Remember that each of these is essentially a morph target, making it a copy of your model. So if you have a SubTool with 15 million polys and 6 layers that ends up being over 100 million polys!
- Too many polys per SubTool. You’ll get better results splitting the model into more SubTools wherever possible.
- A heavily fragmented system drive can prevent ZBrush from utilizing virtual memory efficiently even though there’s lots of disk space.
Also keep in mind that saving as a ZPR saves a lot of data that you may or may not need. It’s the most convenient, but it will save a lot more than just the model itself. That can add up to a lot of memory resources depending on what you’ve been doing. A ZTL saves just the model and any applied maps, which is more memory efficient. It also doesn’t save the Undo History.
Finally, a 32-bit application is limited to 4 GB files. In practice, the upper limit will usually be a bit lower than that. If your file starts pushing 3 GB in size, it’s high time to be looking for ways to optimize it.
I hope that helps!