Are the fields the same height? Same font?
Does the PDF have the defective alignment?
If not then i would investigate the printer.
Kirsty, yea, just went through and checked all of these, highlighted everything and clicked the same font and style. All the rows are the same size.
Coherentkris - the PDF does have the issue as well, which led me to believe it's something upstream from this being produced, so I checked the layout again.
Found a few issues of underlines being dark blue instead of black, so corrected these.
Found a few issues of inconsistency between fields being 'sent to back', so now all numerical fields are at the back.
Then I noticed the 'Slide up when above is empty' checkbox. I removed this on fields which really don't need it and, hey presto, they work.
I have a double underline however that does need this and needs to slide up in the absence of data above. The space between the two drawn lines, despite being the same onscreen AND a copy/paste of another double underline that works in exactly the same way, is wrong. Every other double underline is spaced correctly and slides upwards. This one, even after I've copy/pasted from a correctly working double underline prints incorrectly. Arrrgh!