Hey there! Thanks for the reply. This was my thought too but it seems enabling the cast shadow option only reduces the effect and not completely solves it. I think it has something to do with reflections but IDK what. Still trying to figure that out.
How are you enabling NURMS? I select the object, right click, and from the menu hit "NURMS Toggle" which is the very first option in Max 2011. I don't know if your problem is exclusive to 2010, but there's a chance enabling NURMS in a different way could fix it :)
Enable snap to grid (the snap menu button in the texture editer), then either enable snapping or hold ctrl to toggle it on. You could also enter in the coordinates manually, so if you had verts that were close to the border, you could select them and enter 0 or 1
TGA export with RLE compression enabled. Now DDO seems to export only TGA without RLE compression. A checkbox to enable compression would be fine too. Custom map name suffixes, I'm often working in pipelines that require custom filenaming for albedo metalness and gloss.