A method for forming a halftone image on recording media includes providing a recording head comprising a plurality of individually addressable recording channels. The recording head forms a plurality of image swaths, with each swath formed during a separate scan. A plurality of locations is identified within a representative unit cell of the halftone image. A quantified value for each location is determined based on a sub-scan misalignment associated with a proposed merging of two image swaths at the location corresponding to the quantified value. A merge location is selected from the plurality of locations, corresponding to a desired quantified values. The recording head forms the halftone image on the recording media while merging a first image swath and a second image swath at the selected merge location within a first unit cell of the halftone image.