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I usually do this in Illustrator or Coreldraw and only use Flexi to print/cut. I am sure you could look in the help area for how to do it in Flexi. Recommend using wireframe in any of these programs because it is easier to see the disconnected nodes.
Ok...I just did a quick test on Highway Gothic converted to curves and found several separations. Hope this shows what I was saying. My way of fixing this is to convert to curves and then combine. It usually solves the issue.
Is it all fonts files or just this file? Is this file converted to curves? Maybe check to make sure the nodes are joined and the corners do not have extra nodes. I have noticed on some files sent to us the nodes are excessive and many are not joined. This seems to happen in .ai files frequently.
Could this possibly be a software or settings issue? Maybe check to see that the software and plotter eye is set to read 4 corners. Sometimes the settings get changed during repairs.
Vistaprint.com did some for me a few years ago. Call them first - not thru website - for special size. They did a great job but may not be the cheapest. I went with them for speedy service.
Try getting the profile pack direct from here and then install on your computer first. I believe you are not able to download thru printer first because they are not actually certified for your model number of latex printer. Direct thru Arlon seems to be...
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