That's why when I wanted to have a font that is hinted perfectly for one given size, I in the end had to resolve to baking the hinting distortions into the glyph outlines itself.
Here's my blog post where I explain the problem and my brute force solution a bit more. And you can download the font to see how distorted glyphs optimized for 16px will look at other sizes.
That said, the font editor that I used also automatically runs ttfautohint, so it really is the default tool to get the job done.
https://hajo.me/blog/2021/07/24/making-a-font-that-doesnt-su...