"HCAD doesn't enter your house so they use exterior wall measurements. Appraisers will use interior wall.
Houses are usually smaller when appraisers measure."
Oof. Appraiser measurements are taken from the exterior on single family homes. Always.
CAD can be off because they're estimated off aerial images, given the wrong plans/specs at construction, or no permits were pulled on additions. I've seen some wild stuff.
Appraisers can vary because one can round up, one can round down. But the variance shouldn't be great on accurate measurements. That's the key.
Difficult, large, homes will probably have a greater delta because a couple inches difference can impact things greatly.
ANSI standards are going to be mandatory beginning next month in the appraisal business which should eliminate most rounding variances but no two measurements will ever be exact.