This is my seccond articulated model free supports print-in-place, but the main difference from the previous one (Torbjorn) is on the process that I've followed.
Infact I've started my workflow importing in Zbrush a skeleton from Solidworks that you can get from here.
The cool thing about this project was to show the potential that we can get from a collaboration with two really different softwares.
Start from a template of bones and joints externally modelled in Solidworks and make a decent amount of details on top of it in Zbrush could be a challenging project indeed.
The biggest problems are related with the possible lost in terms of accuracy of the mechanical parts of our model: joints, gaps, cavities that we don’t want really want to modify when we are sculpting the anatomy of our preferred toy design.
One of the key point that kept my attention and patience during all the sculpting workflow in Zbrush was without a doubt the compromise between the overall details placement and the needs to maintain the joints with the same shapes and on the same precise location.
My starting point took form with an initial step where I had to create one polygroup for each articulated part of the template, dynameshing them with high resolution in order to have dense sculpting surfaces.
After this phase the remaining steps consist on analyse each part and evolve the design for it (for instance the sculpt of the muscular arm) without to impact the moving systems of the model. This is why masking, selection and polygroups were so important to complete the project, using them in combination with other Zbrush features as Dynamesh, ZRemesh, Backface masking and of course different kind of brushes to delineate the final design.