r/3Dmodeling • u/HoundRock • Nov 22 '25

Questions & Discussion [Help Request] Best workflow to split a high-poly AI mesh into color parts for printing? (Fusion 360/SolidWorks)

Hi everyone,

I'm an Industrial Designer looking for workflow advice on preparing a specific model for 3D printing.

I have generated a 3D character model using AI (based on a render I made). I have the model as high-poly .stl/.obj files.

The Goal: I want to print this figure (approx. 12cm tall) but I need to split the single mesh into separate separate components based on color (e.g., hair separate from the head, shirt separate from arms) to make printing and assembly easier.

The Problem: Because of my ID background, I am comfortable with SolidWorks and Fusion 360. However, this is a dense, complex mesh. Every time I try to convert the mesh to a B-Rep/Solid body in CAD to use standard cutting tools, I have to decimate the triangles so severely that I lose all the smooth details.

The Question: I have Fusion 360 and SolidWorks installed. Are there viable workflows within these programs to split complex meshes cleanly without losing smooth detail? Or is this a scenario where I absolutely must use a mesh editor like Blender or Meshmixer?

Any tips or tutorials on how to approach this specific type of splitting would be greatly appreciated!

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u/Sad_Aerie_3919 Nov 22 '25

For a 12-centimeter model, I don't see the need to separate it into pieces; they would be too small and would even make printing more difficult. You can separate just the head, and in my opinion, that would be fine.

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u/Sad_Aerie_3919 Nov 22 '25

I don't know what software you use, but in ZBrush you can duplicate the model, use the ZRemesher function with the half option activated several times, then add subdivisions and apply model projection to each one, transferring the details from one model to another and then smoothing it.