Cutting Circular Holes in Curved Surfaces

I’m back! At least for now. Today i’m answering a question about cutting circular holes in curved surfaces. I learned this technique from the great Chris Kuhn a few years ago and have used it ever since.

1.

Start with even quads and an even mesh density.

2.

Add a Circle with an amount of sides relative to the density of the surface.

3.

Add a Shrinkwrap modifier to the circle, and set to project onto the surface area. (Be sure to set the direction and axis of projection.)

4.

Cut necessary areas in surface and merge vertexes along the edge of the hole with the circle. (Be sure to merge to the circle to maintain the circular shape.)

5.

Finish by checking geometry for errors or improper curvature.