Try reinstalling the Suite (Quixel is our company, not our product ;) ) to a new directory such as *\Quixel SUITE 2.3.2\ instead of the default. Let me know if that clears it up! :)
no it's more like generating a dynamic cage on the fly or maybe even with an modifier in the modeling package .. the normal map you get must be renderable the default way of course
Mostly because 3DC tends to delete too much (or changes their values) especially with borders that're close to each other. Example with the mouth area of the default head:
Unity default PBR shader uses a particular layout for glossiness. It has to be stored in a specific color channel. It could be your Shader Forge shader expects the same?
the engine can't read or open the mesh, hence reverting to a default mesh, which is a sphere. can you post a screenshot, exportlog and the asset path that the entity is linking to?
This is "only" a UI limitation. You can edit 3ds Max\Macroscripts\Macro_BakeTextures.mcr Look for "padding" and change the range to [0,256,2] or whatever (min,max,default) and save.