i've had something similiar happen.

it ended being because certain text w/ the font that went wacky was static
and no other variable text contained that same font.

what i ended up doing was typing in one character using that static font
somewhere in a variable box so it wouldn't interfer w/ anything. then i
colored it white so it wouldn't appear.

it ended up pulling that font and embedding it so then the static text
could refer to it.

it might have been a cheap work-around but it worked and i haven't had any
problems w/ the users ordering those items online.

hope this helps!!

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