Outline expands on reopening file

Hi @SajidAttar,

Thanks for reaching out, and I'm sorry to hear you're running into this issue. Just to clarify, when you say the outline expands after reopening the file, did you apply the outline using the Stroke settings or did you use the Outline Stroke command? If it's the latter, Illustrator will convert your stroke into a filled shape, and that change becomes permanent after saving.

Also, this can sometimes happen depending on the file format you're saving in. Certain formats like PDF, EPS, or older AI versions may flatten or expand appearances when reopened. I'd recommend saving your file in the native AI format with PDF compatibility turned on, and avoid using Outline Stroke unless you specifically need to convert it.

Could you also confirm which operating system you're using? And if possible, please share a short screen recording showing your exact workflow, how you're applying the outline, saving, and then what happens when you reopen it. That would really help us understand what's going on and check with the team if needed.

Looking forward to your update!

Abhishek