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Submitted by IronMonkey, and everything stated or implied herein is his and his alone.  Minor adjustments from the original tutorial may have been applied.

Index
   Intro - what you should know first
   Getting Blender - prerequisites and installation
   Availability - which operating systems Blender works on
   Learning Blender - external links to excellent tutorial resources
   Exporting to UnrealEd - how to get your models from Blender to UnrealEd
   Other Considerations - where Blender is usually used
   Acknowledgments

 

Blender – An Introduction

Blender is a comprehensively featured 3D-modelling program. The software has been released under the GNU General Public License and the source and software are freely available.  It can be used to produce complex static meshes that can be used in UT2004 and UT3.  Blender is capable of generating animations but successful export of animations to UEd has not yet been demonstrated.

The purpose of this tutorial is to provide an introduction to the resources available to the beginner user of Blender.  It covers installation, provides links to tutorials, and explains the process required to move assets from Blender to UnrealEd.

This tutorial is written assuming the use of the Windows XP/Vista platform as UEd was only available on those platforms when this tutorial was written. Blender runs on other platforms, including Unix-based systems, but the models produced must be ported to a Windows computer in order to use them with UnrealEd.

 

Getting Blender

Part 1
The first step in getting Blender is to install the latest version of the Python language. Python is needed to support some of the scripts that Blender uses to export to UEd.  (*Note* from IceCreamYou: I have not confirmed that Python is necessary to run Blender 2.42 and above.  The core of Blender, including most of the tools and functions and the ASE export script, will run without Python.  Some of the scripts that install with Blender require Python, however, so I strongly recommend that you install it.)

Python installers can be found here.

Part 2
Blender Homepage
Blender Download
If Blender crashes on start-up in Windows XP, you should try applying [Microsoft Visual C++ 2005 Re-distributable Package (x86)].
The update is not necessary for Windows Vista.

The software required to move assets from Blender to UnrealEd will be covered in a later section.

 

Availability

Blender is available for the following operating systems (note, however, that UnrealEd is only available on Windows XP/Vista at the time of this writing):

• Windows 98, ME, 2000, XP, Vista
• Mac OS X (PPC and Intel)
• Linux (i386)
• Linux (PPC)
• FreeBSD 5.4 (i386)
• SGI Irix 6.5
• Sun Solaris 2.8 (sparc)

 

Learning to Use Blender

Learning to use any 3D-modelling package is hard work and Blender is no exception. Expect to have to invest a fair amount of time before you are fully up to speed. That said, it should be possible to have simple models imported into UEd after a only a couple of hours.  Helpfully, a rich variety of tutorials for Blender are available on the Internet.

I've found Blender 3D: Noob to Pro wikibook tutorial sequence quite useful. Further links to Blender tutorials will be found on that page.  I suggest that you work through the tutorial at least as far as the Quickie Model before you proceed to the next section and attempt to import anything into UEd.
There is an extensive selection of video tutorials at iBiblio.
Youtube Blender tutorials:
http://www.youtube.com/watch?v=ozlwcQT-U20
http://www.youtube.com/watch?v=xYkaHylMPdc
http://www.youtube.com/watch?v=Q7omA7imr1k
There's also KatsBits and others.

After that it's practice, practice, practice...

 

Exporting from Blender to UnrealEd

Blender is a fully capable modelling package and can be used for both static mesh and animation production. At the time of writing, the process for exporting animations from Blender to UEd has not been demonstrated and so that section is a stub until further information becomes available.

Static Meshes
To install scripts in Blender you'll first have to install the latest version of the Python programming language. If you have followed the installation instructions given above then Python will already have been installed. If not then head back to Getting Blender and follow the instructions in Part I.

The bridge between Blender and UEd is the ASE format. To add the ability to export ASE formatted files to Blender it will be necessary to install a Python script in Blender, found here.

That script works with Blender 2.44 and above. There are older versions as well. Once installed (extract the .py script to your scripts folder as defined in your File Paths preferences above Blender's top bar), (re)start Blender.  You should now have .ase as an export choice.

Having exported your model as a .ase file, launch UEd and import it into a package.  (**To be expanded**)

Animations
Animations can be exported natively from Blender in the Collada (.dae) format. Six Ways reports that so far every time that he has tried this, UEd has failed to properly import the skeleton.  However, it may be possible to import this animation into another 3D modeling program and fix this problem.

 

Other Considerations

If all you want is the ability to model and you are not concerned about a career in the game or modeling industry then Blender will suffice for producing content for UT2004 & UT3.

Blender, like other modeling packages, does seem to produce a love it or loathe attitude amongst users. All 3D-modelling packages have a steep learning curve and Blender is no exception. What is clear is that it can be used successfully to produce content for UT2004 & UT3, but like GIMP (a free 2D content creation program) it has a reputation for being difficult to use if you have used other similar programs before.

Most game shops will be using 3DSMax or Maya and so will be looking for experience with those packages. While Blender use does seem to be increasing, it will not (at the moment) offer the same range of options that 3DMax/Maya on the CV will. If you are looking for a position in the gaming or modeling industry then it would be better to learn something like Maya PLE or obtain a student version of 3DSMax (GMax, the free version of 3DSMax, has been discontinued but is still available for download at TurboSquid).

This discussion does not come from direct experience about industry trends but is a summary of the discussion here.

 

Acknowledgements

Some of the material presented herein has been freely adapted (with kind permission) from original material created by Six Ways here.
Thanks to sWs»Cheapshot for pointing out the video tutorials.

 

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