Why does the same seam intersection feel thick and another feels normal? I'm talking about intricate piecing where points join etc. and they are sewn exactly the same way and pressed the same directions. Basically exactly the same with exactly 1/4 inch seams.

Golly not sure......all points cut away?

Did you cut away the selvedges? They feel thicker on many fabrics.

What do you mean by cutting away the selvages, sort of grading like in garment sewing? All points are cut away.

The selvedges are the edge of the fabric. When it's on a bolt, they are the edges opposite the fold. Most will have the fabric brand/style name/number printed on the edge. It's best to cut the edges off before cutting your pieces rather than include them in your pieces. They can shrink at a different rate than the rest and cause puckers.

Sorry. I meant to say seam allowance.