Hi,
We can use Zbrush and its Dynamesh capability to turn a Rhino model to quad mesh. Can the final result be class A model?
No. Not even somewhat close.
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What if we use higher Dynamesh resolution? Then we can even smooth some areas in Zbrush.
Higher mesh resolution is meaningless, if the preconditions for a good surface aren’t met.
Zbrush has some neat algorithmic smoothing tools, but the whole application isn’t intended to create anything precise – let alone to automotive standards.
If you asked the makers of Zbrush what Class A surface is chances are that they never heared that word before.
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No industrial design, packaging design or automotive design quality surfaces with polygons. They’re useful to try out initial ideas in the early stage of a product design development programme.
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Class A is not (only) about “smooth” models. That’s the minimum criteria a model should have. Class A is about explicit control of reflections,visual quality in general and technical accuracy. Class A models in automotive are created in a process lasting months, and are the result of lots of iterative optimizations. If you don’t need class A, then don’t do it. Besides the technical and cad-related aspects its more about constant optimization until a model is perfect. So if you remodel your Zbrush polygon model 24/5 * 6 month then its not class A in terms of automotive standards, but it will definitely be a “class A” model 
(And no, if we speak about the class A standard originated in automotive industry, polygons are not allowed. Since its used in engineering a full mathematical description is important, so Nurbs-, actually Beziers-only is mandatory )
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Well, the same is true with top-tier consumer brands, when I consider CAD/design approaches at Shimano, Volvo Trucks, Samsung, Nike, Airbus or Apple from what I have seen. It’s all about iteration, quality, production to the highest possible level, because top-tier brands command higher price-points and have a strong reputation to defend.
If the client is ok with fuddy-duddy modelling or futzing things, then go for that.
I’m a little off topic, but I’m wondering … How exactly, for example, does Apple use 3D (a high-quality model) in production? Where is 3D in the process of creating a physical object? What does the model give, how is it used? Well, except for printing.
Any company eventually uses 3D data for tooling/production, handling this step by itself or having it handled by its production partners, often both. You can find out about tooling/production via Bing or relevant books.
And briefly can you say the basics?
Please make an effort and use Bing. The field of production/tooling is far too wide for any “basics”. There are hundreds of common serial production methods/derivatives.
Here is an extremely basic primer on injection moulding and here is a super brief introduction into sheet metal fabrication.
Normally, production should have been part of your product design education or vocational production training course, or it should be your design studio’s duty to send you to courses and to the suppliers you commonly use.
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