For starters I see the color space in ACR is set to Adobe RGB so make sure your color settings in PS are set to North American Prepress2 and check all the "Ask" boxes on the bottom.
Using North American Prepress2 keeps the image in the larger Adobe RGB color space.
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To me the image in PS looks crisper than the the one in ACR, but your saying it's the other way around.
When you sharpen in ACR you don't see a difference no matter what you do in the sharpening panel unless you're at 100% magnification or greater.
Holding down the Alt key while adjusting the sharpening or masking can be helpful to.
As for your questions, I never save files as jpg's, I always save to PSD and retain all the layers.
Other people prefer TIFF, it doesn't matter but you should save the image in a lossless format.
When you're ready to print, the amount of additional sharpening (if any) depends on the image, the paper, and your personal taste.
You want to leave the sharpening to the end of the process,
Slipperman summed it up perfectly.
If you start off with a sharpened image other adjustments may not look right.
If your using a matte paper you may want to sharpen it more than a glossy paper, that's where
"Proof Colors" comes in.
I can't recommend a viewer either put if you're going to share the images you can resize, change to color space to sRGB, and
"Save As" filename.jpg
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avz10 said:
For every photo, I would then go to the "normal" PS, but this is where I see the discrepancy between the edited RAW and PS.
In PS, I would do levels, but then I get unsure- should I sharpen more (I like the High Pass filter) as in PS it needs more, as in RAW I was quite happy with the outcome, but not in PS.
I usually use High Pass and then save as a JPEG to print.
I like Hi pass to for sharpening and every image need some sharpening.
I'm confused about the differences your seeing between ACR and PS.
Check the color settings in PS.