For a uni assignment I need to bake my high-poly loot crate to my low. Unfortunately, I'm not having any success whatsoever. For the practise task I had in class, I managed it no problem. With this, nothing seems to be baking. I've tried various things and I'm not sure what or where the issue lies. Admittedly, both of my high and low-poly loot crates don't overlap 100% perfectly. Not sure if that's related.
These are the things I've done so far:
- In 3ds Max, I've zeroed both the low and high (I had to group all the parts of the high in order to zero everything together. After that, I ungrouped them and then reset the pivot and the XForm for each one)
- I've reset the pivot in the centre for both
- I've reset the XForm
- As far as I'm aware, Smoothing Groups have been applied in the same areas and with the same settings
- I created three Standard materials - one for the lid, the main body, and the latches - for the low-poly
- I created a Multi-Sub Object for the high-poly and applied three Standard materials with different colours
- I've UV unwrapped the three parts/UV sets for the low-poly - the lid, base, and latches
- I have similar UV islands overlapping as they're the same. I've also tried it without having any islands overlap.
- I've named them both to loot_low and loot_high respectively
- I've exported them both out as an .fbx
- I've enabled Smoothing Groups, Tangents and Binormals, Convert Deforming Dummies to Bones, and Preserve edge orientation. These were the settings advised to us in our tutorial. It does give me a warning saying that TurboSmooth meshes are tessellated, and there are 7 of them.
In Substance Painter...
- I have the template set to Unreal Engine 4
- The document and textures set to 2K
- I've loaded up the low-poly first
- I've set the Dilation Width to 8
- Loaded up the high-poly
- Set the Max Frontal and Max Rear Distance to 0.1
- I've set the Antialiasing to Subsampling 8x8
- The Match to By Mesh Name
- The Colour Source to Material Colour and applied it to all
- The Ambient Occlusion settings are left at default
However, the end result looks identical to the low-poly when I load it up, with the only difference being the bottom coloured a darker grey. All the attachments/handles all remain low-poly.

I also get an error message saying: Errors have been found while splitting meshes per UV tile: Mesh 'Side Handle' UV coordinates are missing.
Also, if I try and drag a material onto the mesh by holding Ctrl, none of my assigned colours show up. Instead, the bottom is black and the top just shows a checkered pattern.
I'm totally at a loss as to what's wrong. I really would appreciate some help with this if possible.
Thanks