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Unfortunately, like many complicated pieces of software, ZBrush occasionally saves models with bugs in the code that cause problems later on. There is ways of both preventing and repairing these errors. Let's open the DemoSoldier and expand the Subtool and Geometry sub-palettes. There are two main practices that you should always get in the habit of doing. One is to save your models on the lowest subdivision level. This makes it easier for ZBrush to save and reopen, since all the fine detail doesn't have to move in and out of memory at once.
The way to do this easily is in the Subtool sub-palette. Click the All Low button. This drops all the subdivision levels of all the subtools to the lowest level in one click. The second habit is to save your work often and with sequential version numbers. This means that every time you save you should make a new file with a new version number. So go up to File and Save As, and now you could call it DemoSoldier2, and then the next time you save, DemoSoldier3, and so on and so forth.
This is because ZBrush tends to crash at the worst possible moments. And if your latest save gets corrupted, you can probably go back to an earlier save. If you save often and in versions, you'll only lose an hour's worth of work, rather than days or weeks. It may seem like a distraction to save all the time and keep a sequence of versions going; however, the threat of spending hours of work to redo what was lost should be enough motivation to practice these good working habits.
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