How can I completely get rid of borders using geom_sf? (The grids were created with st_make_grid.) I have tried color=NA and size=0, but neither do what I want.
ggplot() +
geom_sf(data = plot_data, aes(fill = as.vector(dist)), color=NA, size=0) +
scale_fill_viridis(discrete=FALSE, name="", direction=-1) +
geom_sf(data = states, fill=alpha("black", 0)) +
theme_bw()
Example:
This relates to: How can I remove border lines when using geom_sf?.

This appears to be somewhat device dependent. I can reproduce your problem on my machine like this:
The easiest way to fix this is, rather than trying to make the lines disappear, simply color them the same as the grid boxes.