A PostScript error: Fontfile not found, offending command: buildchar is often caused by corrupted fonts that are stored on the disks of the RIP or downloaded from the Mac or PC.
Solutions
- If your document contains fonts that are installed on the RIP, they should be deleted, the RIP should be reset and a fresh copy of the fonts has to be downloaded again.
- If fonts are downloaded from the workstation, they should be replaced on that workstation itself. Some servers like Helios EtherShare are also capable of storing printer fonts so those should be checked as well.
- The error can also be caused by a corrupted fontcache on a PostScript level 1 RIP so simply deleting the fontcache and rebooting the RIP might solve the problem.