Flipping Panels
I've seen this... especially when printing solid blues on the SP-540V
I think that you are seeing a slight difference in color from the left side of the print, to the right side of the print. So when you butt the prints together, you are seeing a hard-edge difference in color.
A best practice is to "flip" every other panel in VersaWorks (or Flexi)... as you print them. This way the overlap/butt sides are always printed on the same side of the printer.
What do you think?
~E