Question on sealed box design and stuffing...

Nah, the driver itself will have distortion levels considerably above the effects that might be reduced by stuffing.
A sub-woofer will be asked to do two octaves (at most) and will most likely have some serious low-passing above that.
A good driver and good construction techniques are obviously required. But stuffing is not.......for subwoofers.

Dave.
If the distortion products are significant, depending on the cabinet dimensions, cavity resonances will only make them more significant. Unless steps are taken to damp the resonances.
 
The simulations include these degrees of stuffing: Minimal, Normal and Heavy.

"In the un-stuffed enclosure, we see a predicted Qtc of 0.924. In the enclosure with the minimal stuffing, the Qtc drops to 0.906. In the normal scenario, it’s predicted to be 0.837. Finally, in the heavily stuffed enclosure, the Qtc is a well-controlled 0.755."
I tried this in HornResp and did not get that dramatic of a change... I wonder what reality is. Personally I do not like Damping material, in the sense that if I can design for it to achieve something acoustically without it... I will do that route first... I am currently struggling with the idea that slot of PPSL woofers need damping to achieve the response I like.