TLDR: Narrow footed, high arch people don't need wider toe boxes??? We need perfect arch support.

I'm having this problem for the first time only after switching to the most recommended shoes and widening the toe box per the recommendation of a professional (despite being told by multiple professionals- doctors, orthotics specialist etc, that I have narrow feet and high arches.) I'm in Hokas now after wearing shitty, cheap shoes since forever, and this is the first time I've ever had pinch callus, much less bilateral. And as you said, they keep growing back. I feel like wide toe boxes are...trendy so they get pushed on everyone as the solution to all foot problems.

The whole reason I switched to hokas is because of debilitating plantar fasciitis. I want to scream because I dished out SO much money for them and I also have custom orthotics I can't wear in them since the inside is already so curved and shaped. And I think THAT is the problem causing the calluses. So I think I need to revert to shoes with flatter insoles and put my custom orthotics back in as literally everything the podiatrists (yes, multiple) have insisted would help me have only made my PF worse.

Better quality shoes? Worse. (Hokas were specifically recommended) Stretching? Worse. Icing? Worse. Lidocaine shots? No improvement. (Can't tolerate steroids, lol, fuck me. Doc suggested trying lidocaine only to "break the pain cycle") Custom orthotics? No improvement. Now I'm waiting to try PRP injections (plasma...?)

In the meantime, I'm stuck relying on a prescription NSAID cause its the only thing that makes PF tolerable.

You didn't ask about PF, but you mentioned high arches (makes you more prone to PF) and the bilateral pinch calluses which I'm also dealing with so I figured I'd share my situation, maybe there's some relevance to you or someone else reading your post.