I was using TileCache, but I switched it off to debug this problem. If TileCache generates larger tiles, will there still be clipped labels? Just fewer clipped labels? I don't think this is a workable solution for me, but if I have the time I'll try it.
Correct; there would be FEWER labels clipped (if you force them and allow partials) or missing (if you disallow partials).
How many fewer, depends on how large you make your meta-tiles. If they're 5x5, that's a significant reduction in the number of tile edges. If you really turn up your MAXSIZE in your mapfile, you could potentially make 10x10 meta-tiles; that's 1% as many tile edges.
You could also make your tiles larger. If you have 512x512 tiles, and 10x10 meta-tiles, that's a HUGE reduction in the number of tile edges over single 256x256 tiles.
The only method I know that would eliminate ALL tile-edge artifacts, would be to eliminate tiling, e.g. singleTile:true in OpenLayers. Not that that's a great solution either, but it is sometimes the only way.
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