When setting TPMargin = 0 I get an about 2.4mm margin between the top of the fbox and the TPbox.
With TPMargin=0 and block reference point [0,1] (lower left corner) the positioning is fine with the showboxes option enabled, but shifts about 15mm down without the showboxes option.
Still with TPMargin=0 and now the reference point [0,0] (upper left corner) the vertical shift caused by turning showboxes on and off is about 2.4mm,corresponding to the extra margin mentioned above.
These problems disappear when I set the TPMargin to some small value, like 0.001mm.
Good to know.
\documentclass[10pt,a4paper]{letter}
\usepackage{fontspec}
\defaultfontfeatures{Ligatures=TeX,Scale=.92}
\setmainfont{Lucida Bright OT}
\setsansfont{Lucida Sans OT}
\setmonofont{Lucida Sans Typewriter OT}
\usepackage[absolute,showboxes]{textpos}%
%\usepackage[absolute]{textpos}%
\setlength{\TPHorizModule}{1mm}%
\setlength{\TPVertModule}{1mm}%
\TPMargin{0.0001mm}
\setlength{\TPboxrulesize}{0.1mm}
% #1: height, #2: width,#3 text,#4 hpos, #5 vpos
\newcommand{\onelabel}[6]{%
\begin{textblock*}{#6mm}[0,0](#4mm,#5mm)%
\fbox{\parbox[c][#2mm][c]{#1mm}{#3}}%
\end{textblock*}}%
\setlength{\fboxsep}{0pt}
\setlength{\baselineskip}{0pt}
\setlength{\fboxrule}{0.14mm}
\textblockorigin{0mm}{0mm}
\begin{document}
% parbox: width, height, text, TPbox: x, y, width
\onelabel{40.00}{30.00}{txt}{30.00}{100.00}{100}
\end{document}