It's not a Substance specific problem, nor is a tangent basis issue, it's a basic limitation of tangent space normal mapping. It's an artifact that I generally refer to as "resolution based smoothing errors", you can see some clear examples of it in my big baking tutorial: - Best Results -> Hard Edges and UVs This is something that is typical even with a synced pipeline, but Pior's advice to make sure to verify in the final renderer/engine is sound. If you remove the indented circular element you'll reduce the geometry complexity which should sort the problem out. StG-44 weapon model and animation for a First Person Shooter in Unity 3D, using a PBR texture pipeline. If it will not be seen up close, removing geometry will work too. StG-44 weapon model and animation for a First Person Shooter in Unity 3D, using a PBR texture pipeline. If this area will be seen up close, adding more geometry may be the best solution.
You can also cut in extra edges or bevel some of the geometry in this area so the mesh normals are less extreme. Generally what helps in these cases is to use hard edges at your UV borders, which should negate or lessen the problem, though depending on your UV layout this may not help much.
If you up the texture res you should notice this getting better. Basically, the resolution of your texture isn't high enough to accurately represent the gradients needed to compensate for the smoothing. Generally this issue shows up when your mesh normals are very extreme.
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