I'll list where I'm at right now after talking with the dealer. Nothing is physically wrong with the car. Some answers and some remaining wonderings.
One should avoid using the AC system for defrosting the windshield/cabin because, while it "dehumidifies" really well, current AC evaporator designs can "hold" a lot of water before the condensed water starts to drip into the drain tube. Just google "condensation" to see what I mean.
There's some more optimization that can be done in this space though...
So if you choose or unknowingly use the AC, all that water is still sitting there in your dash. In my and <I think> amphibious' case, we stopped at work or at home and let it sit. It will evaporate somewhat and tend to condense on the windshield on a cold night. This is maybe due to the proximity to the evaporation, but I think it's partially because the windshield has an angle and the other windows on the Spark are vertical. I have noticed that the windshield condensation generally doesn't occur in the region covered by the windshield wiper, telling me that the temperature transfer is helped with dew.
How to get rid of the contained moisture? Pulling in less humid air from outside will do the trick (and is what GM assumes generally), but on a day like today in Portland where it's raining and 95% humidity all day ...
it appears you have 2 options:
* If you're driving, don't try... just keep the cabin cold so that condensation doesn't happen.
* If not driving, turn up the heat and recirc to absorb as much moisture as possible (lots of internal fogging if outside is cool) and then crack windows to let it out.
Not sure why I don't notice the overnight windshield condensation on gasoline cars as much yet. Possible suspect is residual engine heat, of course...
Hope this helps!
EDIT: amphibious, if this fixes your issue, can you edit your top post to include a summary and a link to this post so people can find it a little easier? Thanks!