Considerations for vertex cities
military
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Yes and no: For a high resolution map and versatile terrain there are nearly no game situations, where a player would notice the deviation from the great circle path as something obscure: Because to notice it, one would have to send a unit at least n tiles far away and all tiles in the region between the start and the end tile would have to be the same terrain or, more precisely, cost the same movement points. However, there are some important exceptions: Ships on oceans, helicopters (what are their movement points in comparison to n?), and the tiles you choose to build long roads through your empire...I don't see it as a big deal IMO.

Hmm. At the moment there are 6 poles with 4 overlapping hexagons each and 2 tile-based straight great circles crossing at each pole. This gives in total 8 270°-triangles, which are filled with hexagons. I do not understand what you mean with "interpolating between six longitudes"; if you join 6 straight hexagonal tile paths, you end up with a single hexagon in the center (compare the 8 dual poles, i.e. the centers of the 8 270°-triangles in the maps above); but this is probably not what you meant...?Would it be possible to create a map by interpolating between six longitudes created by two hexagons at the poles?
Imagine the three great circles, which slice your orange into 6 equal pieces: They will meet on the North and South Pole in a single hexagon each. So far, so well. Additionally imagine the equator. This results in six triangles on the sphere's surface on each hemisphere. The equator is also a great circle, i.e. it must have the same amount of tiles, say m. This results in each triangle being bordered by m/4 tiles on two sides and m/6 tiles on the third side. Now these triangles have to be filled with hexagons, but this would only be uniformly possible, if all three sides of the triangle were bordered by the same amount of tiles! (Compare this image to see why.)slicing an orange into 6 equal pieces
Certainly not: The deeper reason can again be seen in 2D already (above image link): If you stick to uniform tiles without gaps between the tiles and choose an arbitrary starting tile, then the actual distance from this starting tile and the distance-in-tiles is direction-dependent, which is intrinsically incompatible with a sphere and can only be solved by deformations. This is the local reason, why deformation cannot be omitted. Additionally there is a topological/global reason for deformation: The base geometry, i.e. the defined neighbourhood net between the tiles and the placement of the artifacts, also require deformations. These topological deformations are not uniform (only 90°-periodic in my case), which can cause discrepancies between the real distance and the distance-in-tiles to accumulate(, which is again the unsolved problem depicted above).Is it possible at all to tessellate a sphere without any deformation of the tiles?
The source code I posted above is a bit more current than the last pictures. In it I have played a bit with the projection formulas again and actually reduced the global deformation a bit in the sense that the distance coloring now is more convex for non-polar starting tiles, but this was only possible at the price of giving up the circular tile positioning around the 6 poles (which I chose for optical reasons). If you want and have a working Matlab installation, you could download the source code and try your own projection formula, because at the moment I am out of ideas....
Well, getting paid for a hobby project would certainly be welcome and also particularly useful for my real-science projects. 
Is there another tile shape you could use besides the hex to get around the issue of having 'poles'?
The only convex, regular polyhedrons (the only kind that the surface of a planet could use)...