72x72 pixels? That´s nothing. No wonder you can´t get clean results. Depending on what you want to do with it, you can have you alphas way bigger (try 512).
Shepeiro: Thanks for the advice the renders look light years better with a little color, used pcount green, orange and a light blue skylight. Ok here ya go skin 6272 with eyes, hardware rendered -Woog
The UVWs have quite a bit of room available for use. It's generally a better idea to place UVs right next to each other. Sometimes rotating them a bit or using some Tetris logic to fit them as tightly as possible is required. For the UVWs, the scale should never be rectangles. It should always be perfect squares. The way…
using: http://www.polycount.com/forum/attachment.php?attachmentid=5272&d=1344062369 first view is from the UDK morning scene. second is from Maya. may update later.