I then took the SU cannon into 3D Coat and added distress. There were three objects, one for each material (wood, bronze cannon, and metal). OBJs were exported and UVs added automatically in 3D Coat.
The model was exported as bake targets for Substance Painter and there materials applied, then exported and rendered in Unity.
Next the model was tweaked in SU to create a low poly version and baked and mapped again in Substance Designer. Here are the two high poly and low poly versions of the cannon side-by-side in Unity.
Then, the model was voxelized and tweaked in 3DC and made an entire solid for 3D printing. Many of the features had to be 'supersized' in order to meet the material thickness threshold requirements. Here's the under 1M poly finished 3D print model in 3D Coat.
Finally, colors needed to be added for 3D printing in Substance Painter. The same bake targets were added and then adjusted for the supersized details. Also, I only used diffuse maps (no normals, metallic, smoothness) as the color Sandstone material would not reflect the other qualities. The model was mapped, exported to MeshLab and converted x3d for final upload to Shapeways.
Here's what it should look like when I receive it.
Here's a video describing some of this process:
https://youtu.be/YnPRa9p2fQY