Baking errors on sharp edges

aaeriam

Hello friends \o/
So I'm pretty new to baking with substance (and baking in general) and one problem I keep running into consistently are these sharp black edges on round surfaces. I think I can just add more edge loops to smooth out the mesh but is there anything specifically I should/can do to avoid this problem? 

Froyok

My guess is that is it because you have a very thin surface here with vertex normals that probably points outward and very low geometry. So basically what happens here is that no rays hit the high-poly mesh and return therefor and incorrect normal color in the final texture. You could fix that by adjusting your low-poly silhouette, by adding more geometry on the low or by adding a thickness to the border of the blade.