Some filters are not tile build friendly. They show an "exclamation mark" next to the device name. Try to avoid those.
Also, erosion filter with "geological time enhancement" enabled, creates drastically different result for tiled build. Try to avoid that option too.
Solution: The best 1:1 result can only be obtained by cutting up a hi res result "after" the build is baked to files. You can set up a file in world machine with "file input->file output" set for each file you want to split into tiles (including masks). Then set up tiled build for that new world. That way you can split as many files as you want, as many times as you want, without losing details. Do remember to disable blending in the tiled settings, and enable "share edge vertices".