I have to do some relatively low res assets - at 2.5 px/cm. Usually with hard edges and normal map baking it's common to see a tiny little seam if you zoom in A LOT on them or if the texel density is low (it's not really a problem in most cases). However, this doesn't happen if baking in Maya - even at super low resolutions, the baked edges are insanely smooth. Has anyone figured out why, and how to bake them the same way in other programs?
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Are you using the same texture resolution in both versions here?