Ok, we're not going to draw fresh from news this time around. Instead I'm going to recall my own trials and tribulations and offer up some advice on producing your own wonderful designs. Detailing how to avoid the troubles I had to deal with.
1) Double check your models for holes.
I actually didn't have any problems here however, I have found helping others, this is a common problem. Tiny holes can really screw up a print so always double check your model for holes. You can use functions like Cap or Patch in Rhino/Matrix. While the Close Holes option in Zbrush will fill in any undesirable spaces that you may have accidentally left behind using Dynamesh on your model.
2) Double check your file types.
Before you throw your computer out the window trying to upload your precious 3D model to service sites like Shapeways. Check what file types they take and what your program saves them as I've accidentally gotten enraged at Shapeways for mistakenly trying to upload .3dm and .ztl files several times. Most print service sites like Shapeways take .stl/.obj files. Most modeling software also have the ability to save in those. These are the two formats I usually default to. Of course if your site requires other file types you may have to use converters like netfabb which you can pick up for free.
3) Check your model's walls.
This is one that put me in multiple pickles. A lot of my models have had issues regarding "thin walls" It's not something a designer thinks about consciously, while attempting to create art. You don't want to be spending weeks in limbo with your print service trying to fix thin walls. This is less of a problem for designers using Rhino/Matrix and more of a problem with heavy Zbrush users like me. Pixologic hasn't included a real life grid measurement system so always double check your wall thicknesses before uploading. It'll save you a lot of time and heartache. Programs that are especially designed for rapid prototyping work will have less of an issue with this as there are built in measurement tools and customizable sized grids.
Increasing wall thickness in Zbrush is fairly easy, functions such as Inflate in the Deformation tool menu can easily fix some of these thickness issues. Just be aware that it may distort your model a little. Be prepared to re-adjust your model accordingly.
Likewise in Rhino and Matrix you can simply go back to your curves and re-size them before extruding into a surface. Similarly you can use T-splines to try to manipulate them accordingly.
4) Double check the size of your model
This one is pretty self explanatory. But, I actually goofed and almost printed what should have been a 60mm across bracelet as almost a 30mm across bracelet. That would have been a really tight fit XD Luckily orders are easily cancelled at Shapeways so when someone pointed my mistake out I was able to quickly re-upload the appropriately sized model.
Rhino and Matrix has multiple ways of scaling using the Gumball feature you can simply scale your model accordingly by dragging the tiny square at the end of the arrows. Or you can use Scale 2-D/3-D depending on what you need to increase.
Zbrush has similar scaling mechanics with the Transpose tool in the move menu. However, it's best to size your model before bringing it into Zbrush to sculpt.
5) Double check your site's upload rules.
Some places don't allow X-rated materials to be posted. So always double check lest you wish to get in trouble by breaking TOS (Term of Service). If your site does allow X-rated material, great. Then you can probably ignore this rule.
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