I am finishing up my layered typeface and have stumbled into a problem I can't seem to solve. I first thought there was human error involved (still possible in some instances) when I exported the font family in OTF format—but then I exported to TTF and saw there were fewer problems. Here's what's happening and here are some details.
1. This is a layered typeface that was drawn by hand with an ink brush, scanned, and then cleaned up some—so it is constructed rougher than a typeface done entirely in FontLab or Glyphs.
2. On the interior layers the edges are off register "ever so slightly" in OTF format—but they are "off ever so slightly" in MANY places and on different layers. This does not occur on every glyph.
3. The edges are off "ever so slightly" in TTF but in DIFFERENT places—and to a lesser degree.
What I'm trying to figure out is:
Why is this happening?
Why are there differences in the outlines between formats? (These have to be EXACT since it's handdrawn.)
And why does the TTF export have fewer errors?
Finally—when I say "slightly" off—I'm talking off by "pixels." I also receive no error messages in FontLab when exporting.
Any help here would be greatly appreciated. I'm banging my head against a wall here.