This looks like an issue with UV smoothing. Are you baking down to a sub-divided mesh? If so, why? It looks like your uvs are being smoothed in the middle of the uv islands but not on the edges.
Also, where did you bake your normal map, and onto which mesh?
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Also, where did you bake your normal map, and onto which mesh?
I baked my nm in mudbox, onto my low res model.