Editing foreground masks

One of our more “dreaded” activities is having to make changes to a foreground mask image in the designer. We’ve talked of this previously. Just touching those things in any manner can have an adverse effect on past orders revise or loading previous designs and templates when loading again into the designer.

It has been a while since we discussed, so checking if there might be any new ideas. Ideally we would love to delete the ancient masks for some products and do away with them entirely. There are now some better methods for doing what we want to do without using masks.

Might there be some new idea to force every previous design that used a foreground mask to load into the same boundaries of the old interactive margin tool settings to fill the current product size parameters?

There's no magic here unfortunately, just math.
Foreground masks are just images, but if in this you will be changing the margins, you're changing the "coordintate system"... and If you change the "coordinate system", there's really not much to saving past things.
Only way would be to keep the same exact sizes (or at least proportional), but looks like this is not an option for you.
But altering the product's size will cause unwanted results almost for sure.

The good news though is that orders are saved as absolute values.
This means that, in general, if you REMOVE margins from a product, the design will look the same. This because you'd be really adding more "canvas", just like in photoshop.
But if at the same time you will also change the proportions of the designable area, then RTD will have to adjust (and more likely distort)