Problem:
Unwanted/duplicate text characters (such as the letter "t") are being added to the report when exported to PDF. A printed report and exporting to text seems to be fine.
Solution:
After doing some Googling, this is a known, specific issue with Calibri fonts going to PDF. The easiest fix is not to use that font. If you want to dig in and make it work, Google/search this:
calibri font pdfs
and then maybe this:
calibri font pdfs usp10.dll
Here is a direct link to the issue being discussed on SAP/Crystal's site:
http://forums.sdn.sap.com/thread.jspa?threadID=1272660 or https://community.sap.com/t5/technology-q-a/calibri-font-inserts-extra-characters-into-pdf-version-of-report/qaq-p/5309143
https://userapps.support.sap.com/sap/support/knowledge/en/3123372
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Some Debug and Fix Options (Based on Searches and Links):
Quick confirmation of issue and quickest/easiest solution:
Change the report font from Calibri to something like Arial or Tahoma and export again. If the extra “i” disappears, the issue is Calibri.
Fix the usp10.dll issue (older Crystal runtimes):
Ensure the Crystal runtime loads its own usp10.dll from the Crystal installation folder rather than the Windows System32 version. Copying or forcing the correct DLL into the Crystal bin folder often resolves the problem.
Registry fix for newer Crystal versions:
Add a DWORD value named UseCustomEncoding set to 0 under the Crystal PDF export registry key (typically under HKEY_LOCAL_MACHINE\SOFTWARE\Wow6432Node\SAP BusinessObjects\Suite XI 4.0\Crystal Reports\Export\PDF). This tells Crystal not to use its problematic custom encoding for PDF output.
