We had similar problems but not to the extent you posted.
We set up our mosaics at PA=0. Then I calibrated the rotator with plate solves. This helped a lot although not completely. We use an overlap of 8 degrees.
When a mosaic is shot, each panel in a vertical column of tiles will be similarly aligned, the adjacent column will be slightly tilted, the next column over will be tilted more. If you number an 3x3 panel mosaic like a tic tac toe grid with 1 being at the upper left then 2 the upper center, etc., then panels 3, 6, and 9 would be identically aligned, almost perfectly. Panels 2, 5, and 8 would be rotated relative to the first column panels, but would be rotated identically to each other. 1, 4, and 7 would be the most rotated relative to the panels in the first column but, again, those 3 panels would all show the same degree of rotation.
Careful calibration of the camera and rotator to PA=0 with plate solves allowed us to get a 9 panel mosaic with a 500mm Tak FSQ106 using an 8 degree overlap. Our target was close to the celestial equator. I suspect the rotation problem gets worse as a target is selected that is closer to the pole but we have not tested that. I don't know why the problem exists. The mosaic as displayed in TSX looks perfect but the resulting panels in the light frames don't agree. We exported the layout straight from TSX so there was no opportunity for us to introduce the error.
I hope this helps. I wish I had a fix to offer you.
Best,
David