I agree a slightly different size should make no difference. I don't see how it could. Mizuno recommended using about the same mass of material, in a stack 3 meshes high. Or higher. The amount of Pd deposited probably matters, but I expect it varies a great deal from one sample to the next.
Handmade samples are bound to be highly variable, with a random distribution of material. That might actually be an advantage at this stage in the research. As I wrote elsewhere:
The mesh geometry may be important. A mesh will have Pd in one area, then no Pd, then more Pd. It will have many edges where Pd ends, and Ni is exposed. Mike McKubre suggested that D may be coming in through these edges. In contrast, a flat surface covered with Pd may have few edges or gaps.
A mesh will also have very uneven coatings of Pd. Thick in some places, thin in others. If there is a specific depth of Pd which works best, there will be places which have just the right depth. Other places will not have it, so they will not be activated. If the depth were more even throughout the material, it might all be at the wrong depth. Since we don't know what depth is best, this random selection of depths may help.
It will also have variable amounts of NiO left on the surface or pushed away. Again, if it turns out this is important, it is good to have a sample with a broad range of NiO thicknesses.
Assuming the thickness or the distribution of materials on the surface is important, my guess is that if you could manufacture a sample with some high tech tool used in semiconductor fabrication, that produces a precise configuration of materials at specified depths very evenly distributed, you would pick the wrong depths, and the device would not work.