Actually, no it hasn’t been, since I was unclear on its benefits and it does seem to increase render times somewhat. But some test renders of the same frame with Full Osa enabled on both materials at the intersection shows that it doesn’t fix the problem – the ragged edges are softer (sort of like upping the OSA sampling value) but not eliminated. But thanks for the suggestion.
A half-day of running tests on Materials, Mesh and Lamp settings seems to show that this is not something that can be fixed with any one setting. I did discover that the the angle of the lighting has some effect – when the edges of cast shadows don’t fall very near the mesh intersection, the raggedness vanishes.
However, by adjusting the lighting so no shadow is cast, the ragged mesh intersection is clearly visible:
However, the angle of the mesh intersection may have some bearing on the problem, since the raggedness does not show badly at all places along the intersection of the meshes.
Here’s a theory on the cause, and why it looks worse when shadowed: At the intersection, the rendering engine has to make a choice whether a pixel being rendered belongs to one mesh or the other. Within a range spanning a number of pixels on either side of the intersection, the color and shading of the pixel to be rendered is ambiguous. So some pixels in this range get assigned to one mesh, and other pixels to the second mesh, but the choices seem to be a bit random within that range, leading to the raggedness. When shadows fall in this area the effect is magnified by both the contrast between lit & shadowed areas, and maybe also by a similar ambiguity, which may be of a larger scale, in the calculations of the shadow’s soft edge.
It doesn’t seem to be tied to the mesh resolution – when I upped the Subsurf level of the figure mesh, it made no difference at all in the appearance at the intersection. Changes to Camera settings (Lens, Clip, etc.) also had no effect.
In another 3D app I used in the past, there was a setting for the renderer that would create a small-scale gradient blend/blur between intersecting objects, smoothing over this kind of raggedness to a large degree. Is there anything like that in Blender’s toolset? Or, is there some way to detect mesh intersections in a way that could be used in the Compositor to modulate a Blur node to sort of smear the problem out a bit?