Sorry - just noticed this was over a week ago - have to keep up with the Slack 😞
Anytime we refresh sandbox, I have to delete the IDP metadata file from prod & sandbox, and then re-import the IDP file. Once I do that, users can switch between Sandbox and prod from role selection when the have logged in via SAML (provided they have been granted access to both).
NS uses the same IDP file for both