Texturing large aircraft

Hi all,

Background:
I create aviation safety videos and typically purchase helicopter models from Turbosquid, then rework them, mainly redoing textures in Blender with decals. I am still fairly new to Substance Painter, so please bare with me for any stupid questions that might be resolved with common workflows.

Goals:

• Produce highly detailed, accurate aircraft models.
  
• Use textures (rivets, panel lines, etc.) to replicate fine details while maintaining accurate placement based on the real aircraft.
  
• Begin marketing my models on Turbosquid as more accurate, professional-grade options.
  
  

Current workflow and challenges:

• Texture size: I have been using 8K or 4K textures, which generally works well, but rivets lose sharpness in close-up shots.
  
  
• The model I purchase usually have one texture map for external surfaces.  However it starts to create issues when trying to focus on details like rivets and screws. To improve resolution, I have been splitting models into multiple UV maps (for example EXT_TAIL, EXT_DOORS, EXT_FRONT) or I've been using decals in blender for logos and stickers - I'm worried that this might be overkill. There is an easier way to have these details without using additional texture sets.  If so, please advise
  
• Livery alignment: Many aircraft liveries need to flow cleanly from the tail through to the nose. Maintaining crisp, seamless lines across multiple UV sets is tricky.
  
  

What I am looking for:

• Recommended workflows for achieving sharp rivets and panel lines without massive texture sizes.
  
  
• Best practices for handling aircraft liveries that must flow seamlessly over multiple texture sets.
  
• Techniques for softening edges in Substance Painter that will apply a slight bevel effect to edges, similar to the “soften edges” function in V-Ray.
  
• Advice on balancing texture resolution, UV layout, and efficiency for models aimed at professional resale.
  
  

Thanks in advance for any tips or workflow suggestions.