Issue: We have a report that uses an IDAutomation barcode font. The report renders correctly, but when exported to PDF, the barcode is drastically shrunk and unscannable. In Crystal 11, this issue has been fixed with a couple of registry entries but we have noticed that you may be calling a different DLL to export to PDF.
Solution: Add the following registry key...
HKLM\SOFTWARE\SAP BusinessObjects\Crystal Reports for .NET Framework 4.0\CRYSTAL REPORTS\EXPORT\PDF\ForceLargerFonts
DWORD Value: 1