Thanks for the reply, I should have mentioned that I do test them - in Unity3D, which is where the assets are primarily meant to be used. I just tried smoothing groups again and now it actually made a huge difference: My normal maps look pretty ok now. I'm aware of the increased vertex count, though. I don't currently have…
Thanks for the tips, I tried xNormal as well, but couldn't really get that much better maps out of it, so for now I'll stick with Max. In Max I've been using the cage for now and things really started rolling, when I tried the export/import feature - so much easier to edit the cage when it's a separate object. I Can't…