Has that caused you issues or do you not build your models for smoothing? Sorry I didn't reply directly to this the first time it was asked, I honestly didn't have a clue what you meant by building for smoothing. Now I do! The answer to your question now is yes! I do build my models for smoothing, or at least I've just started doing so. I've been reading more and more about game asset creation and have, for some reason or another, only just come across the concept of smoothing the hi-res mesh before baking normals. Anyways, I tried it a few times myself (the cut-faces tool finally comes in handy!) and it really does boost the quality of your normal maps, lovely and smooth, with very few harsh anomalies which I would sometimes get from unsmoothed hi-poly models, particularly on corners. Here's an oil-drum I did last night, haven't had a chance to use the technique on any of my more complex models yet (only known about the smoothing workflow for 24 hours), thanks, Martin.