Last night I started working on an experimental tile edge adjuster. What it does it takes the tile mesh, extrudes and shrinks the thing from its edges twice, by a set value. In this case I shrink by 5 cm on each side. Then it switches back to the other edges and unshrinks them by the amount they would have moved, putting all non-edge verts right back where they started. Basically this just creates two tile edges inside the tile edge, so that the smoothing functions can make an easier flat face near the outermost edge. I then had to maximize the flatness on Z axis rises by adjusting the positions of the verts so they lined up exactly with the x or y position of the outermost edge, or there was some weird angle pointing back toward the center of the tile. If you'd like to try it on a standard tile, run this function in gmax. I'm exporting tiles now, just to see what happened with the edge details. Last night's trial was not sufficient, so hopefully this double edge and edge line hair perm will fix the deal.
Edit: while interesting, the function run with f1 set to 10, and full smooth on the tile, was not sufficient to cancel tile seams entirely. It was much better than the 2cm test from last night. I'm currently trying 25 and 50 just to see what I get, or if the overall smoothing curve is actually changed by distance. I suspect it is, but only to an extent. The longer the curve, the more horizontal the edge normal will be. There must be a really good combination of two, or an easier combination of three, which will deliver exactly what I need.
Edit: not exactly a lesson in futility, but getting somewhat close. Combinations of any range which total 25 or more centimeters from the edge also interfere with the geometry, making it so the walkmesh no longer lines up with the model, or creating an even worse seam or near seam obviousness.
I think reverting back the current release and having NO smoothing from tile to tile will be actually a better look. Feel free to play with the function above. Adding another level of face extrusion and transform does increase the smoothness at the tile edge. To further smooth the tile edge, I played into the underlying waveform of edge smoothing by only requiring the second-to-outermost edge to be adjusted on the x-y plane. I tried that from 10cm down to 4cm, with 4cm being more useful looking.
Anyway, abandoned and moving on. Time to play with a custom shadow box builder. This one should be far simpler to implement.