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A partition based on a sparse disk image might avoid that.

You'd have what appears to be a 128GB image (or some large fraction of that), which in reality is largely holes (typically: repeated blocks of ASCII 00 bytes).

Of course, you'd need to avoid actually trying to fill that filesystem.

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There are ways around it AFAIK.
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There really isn't. You can try avoid the "30GB volume on 128GB phone" problem by putting the hidden volume inside the free space of another volume, but since the outer volume doesn't know about the hidden, you have to be very careful not to overwrite the inner volume contents. The safest way would just be to not use the outer volume, but that's also suspicious. Who carriers around a phone that doesn't have any activity for months/years? Not to mention trim/discard means that free space will get wiped by default, and disabling it also makes you stick out like a sore thumb.

You're better off traveling with a wiped phone, and restoring from backup after you've crossed.

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Who carriers around a phone that doesn't have any activity for months/years?

An activity-generator might help address that.

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Well the activity generator is going to have to be very careful to not accidentally overwrite data on the hidden volume, and somehow able to hide itself from adb or forensic tools that it's enabled.
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Those are ... relatively minor concerns.

Firing off as part of a duress key entry, and removing itself (from the decoy partition) as its work is done, would suffice.

ADB / forensic tools would be ineffective if USB access is denied (as discussed elsewhere in this thread).

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>ADB / forensic tools would be ineffective if USB access is denied (as discussed elsewhere in this thread).

Well no, because if you gave the pin, you'd expect the phone to work normally, including enabling adb. If you gave the pin but adb doesn't work that would be massively suspicious. Same if adb worked but logs were scrubbed. Otherwise you're back at "border guards found out you gave a duress pin, now you're being prosecuted for tampering with evidence".

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Right, it would have to be 64/64 for everyone.
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