Hi Michael. Thanks for the insights, always helpful. The font curves have been extruded so there should be adequate overlap. I looked at the vector letters a bit looking for something that could explain, but don't see anything. Flow can result in different results without changes to what is being flowed ? I've uploaded the .3dm file to google drive below.

https://drive.google.com/file/d/1ft0DPWiWj6PtQcIzxRYjSk-k0xyRsS5z/view?usp=share_link