Print doesn't match pdf
I'm making a text mosaic of 8-in blocks on a wall. I created an indesign file containing letter shapes filled with a rainbow graphic, and saved it as PDF.
I created another indesign doc that expands the first pdf to about 1200%, with each letter divided into four 8-in blocks on each of 4 pages. The original letters had a black stroke, which is clearly visible, but the cut edges where the letters are divided have no stroke [see image 1]. Saved that as PDF.
When I print the second file, everything looks fine, except the cut (masked) edges of the graphic have now gained a stroke similar to the one on the edges of the letters, but about half as wide. [see image 2.] They do no appear on screen in the pdf.
It seems the printer is misinterpreting someing in the PDF file. Is that a bug in the printer, or is there something wrong with how indesign is saving the PDF? Can anyone offer an explanation of how this could happen?

