I've been meaning to make a post like this, I finally got around to it.
I can't really compare, because I don't have samples of smooth and aligned chips, but I can tell you about my non-aligned textured ones.
They're awesome.
I ordered non-aligned, and I just grabbed one of my 100 ct. racks of 25 chips, every chip in the first column is almost perfectly aligned. Out of the 100, I picked out the six worst ones, and took pictures of them.
The surface of the chip has a good ceramic feel, but isn't as smooth as Chipco obviously because my WSOPs are textured (I'm comparing to Chipco 2004 "Tournament" WSOPs) - also, the edges are a little sharper, and of course no white ring around the top of the chip like on Chipcos. Best of all, no spinners in my batch of 525 Mr. Chips. My 10-chip sample Chipco set has 4.
Chipcos edgespots aren't aligned. It's impossible to get them aligned. Even when ordering my non-aligned, about 30% of the chips appear to be dead perfectly aligned. Another 65% are very very close. The other 5% aren't aligned at all (two of the six 25 chips mentioned earlier are this way)
However, with the non-aligned chip, you may experience just a little bit of bleeding on black stripe/yellow chips, such as the 1000 chip, and 10000 chip, but not very much. The 100 chips also look a tad big foggy on the stripes, with the black chip/white stripes.
The Mr. Chip samples I ordered were all very far from aligned, so I'm not sure if the sampled non-aligned will give you the same consistency as the actual order. I'm also not sure how many of his orders came out this close to aligned, but I couldn't have been happier with how mine looked.
Here are the other four denominations I have, I grabbed one chip of each at random for edgespots.
I also stacked 10 Mr. Chip samples next to my 10 Chipco samples, and the Mr. Chip stack is a tad bit higher.
