3D Printing Making joints in Nomad Scuplt ?

Do you feel the parts are sized correctly overall and only the joints don't fit together right?
If it all seems good but just the joint / connection is a wrong size I would first guess the joint smoothing went wrong somehow.

I have no experience with the programs you mentioned but it sounds similar to what I do in blender:
1 Make actual part, like the whole arm
2 Make ball etc "cutting parts" for joint, such as a bean and string pipes for elbow, use those with boolean to separate parts / joints from actual part
3 Check how parts look after getting separated, smooth any offending sharp edges with sculpting tool
4 check fit again with the original "cutting parts" from step 2 - if remember... And boolean again as needed.

I sometimes smooth too much and joint becomes too deformed to fit, which I only notice after printing because I forget to do step 4... yeah not very good at this yet.
Once I printed a leg socket but forget that the socket has to be big enough to insert the leg! It's not enough to have the space for ball, also need a ball shaped and sized PATH to the socket... and also room to turn around It sounds so super obvious but I keep forgetting because too excited to see it printed
It sounds like from your description that you do those kinds of checks already though. Maybe someone familiar with the specific programs has better info.
Do you think it might be the parts don't fit in the 3d model itself, does anything seem to change size or shape in the slicer, or is the problem visible ONLY after printing?

 

Hi! Love your printer choice, I have one too!
Speaking from the aspect of rigid, sharp edges on mechanical parts (instead of organic things like curves on BJDs) there can be issues of the resin building up and essentially clinging to itself and making a part bigger. I don't know if that is your problem, but it is something I take into account when printing mechanical parts from Fusion360. I have printed 4 BJDs and after the first, I began mitigating the issue by shrinking joints by 2%. This really isn't a good answer, and perhaps you could check your anti-aliasing settings? but it is a quick solution I have used

 

Oh my goodness!! They are both so beautiful!! I love the faceups! Also the body shape is gorgeous

 

I've been fussing around with nomad recently so it's super cool to see some dolls sculpted with the program, and OMG are yours adorable!!!!!! I absolutely adore the aesthetic.