I've enjoyed reading...
So far I do everything from start to "ready to simulate" in Blender, then move to Poser. It took a LOT of getting used to, but I have found Blender's UV Editor to be fantastic. If you are really worried about seams, you can take all the vertices of a hem, line them up individually on the UV map, and then take all the vertices from the other side of the hem and do the same. Usually I don't, though, because I try to avoid seams as much as possible. One other neat thing I discovered in Blender, is if you model only one half of the outfit and set up the UV layout then, when you use a Mirror modifier to create the other half of the outfit, the UV is created automatically for the other half, and it is a perfect mirror image of the first half. Translation: texture maps meet perfectly at the center, and as a bonus, the texture artist has to only put together a map for half the outfit.