Thanks for the quick reply. Like I said in my original post, the map I’m using to project is 3000px wide (and 2292 high, so it’s taller than 16:9) so in theory it’s much bigger than my 1080p comp. (and I tried an even larger 5000+ wide random image with the same sort of results) It’s 300dpi in photoshop but after effects doesn’t pay any attention to that does it?! :-S And i’m using the maximum 4000 shadow map resolution in the comp 3D settings.
I did some more experiments and turns out a AE text layer also casts non-crisp shadows in the same comp.
A wider camera angle definitely seems to improve the sharpness of any of the projection maps/shadows I’ve tried so far. my original problematic attempt was arbitarily a 35mm camera, in my tests I tried a 20mm one to much better effect. Changing the camera angle messes up my original half-built comp of course but I think* it doesn’t really make any difference if I start again in a new comp with a wider camera.
(*it’s too friday afternoon to quite get my brain around whether the camera angle even makes any difference but I think I’m correct that it’ll just mean the grid solids i line up will be a different size/distance from the camera?)