You'd also have more luck getting responses if you posted this in the Quixel section of the forum and not in the Allegorithmic Substance portion of the forum.
Hi @BucketOfNuggets ! if you use Substance Painter, there is this tutorial from Allegorithmic that explains export texture process, maybe it can be useful ;)
IIRC, the newer NVIDIA cmd-line has an algorithm improved over the PS plugin's algo. There are other algorithms, but if you're stuck with DXT1, your image quality is gonna suck no matter what. You need to fight for DXT5_nm. It does a much better job simply because its alpha channel uses a higher bit depth than any one of…
Found some to participate to the Allegorithmic during my lunch breaks, here's my entry about texturing this little guy in Substance Painter: Meet Commander MAT17 ;)