TF2 Style Guidelines
Couple of things to keep in mind when building things in the TF world.
Theme
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Keeping the visual style consistent is important, in that we don't want anything out of theme or out of date.
TF is a stylized world set some time in the 50's. Nothing modern, visually hyper-realistic, or overly "cartoony."
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Maintain character personality as much as possible with items.
Hats should maintain the character personality of the wearer (heavy ushanka, scout batter's helmet, etc.)
Modeling
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TF generally has realistic proportions, only slightly skewed to add visual interest to certain areas.
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Details can be slightly overscaled or underscaled, or even removed if unimportant.
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Keep things simple and clean, just enough to identify what an object is.
Texturing
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Maintain the same texture density of other models in the world (Nothing higher res or lower res than what's next to it.)
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For hats, maintain team colors, if not - neutral colors (see color swatch below.)
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Character textures are less noisy/detailed than everything else in the game.
Character items/hats should match that style.
Technical Info
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Keep the polycount similar to what's already in the game.
Try to keep hats under 800 polygons, and weapons under 8,000.
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Texture sizes should not be larger than 512x512.
For hats, 256x256 is usually large enough.