Bug in Photoshop Layer styles becoming jagged on export or rasterization.

[EDToShred]

I'm having a panic inducing issue with Layer Styles. I'm making a large banner 18 ft X 7 ft. On my poster size version of this image, the second image down, everything looks fine. I'm using a combo of strokes and drop shadow in Layer Styles to add the outlines to the words in the image below. Looks fine in the poster version. In the large psb version for the banner output. When I try to export or rasterize the layer style the drop shadows go to hell. The edges become wildly off and jagged as seen in the first picture below. How can I get around this? I need to send this to print ASAP to have these banners in time for the 4th of July.
Thanks!

[c.pfaffenbichler]

Could you please post screenshots taken at View > 100% with the pertinent Panels (Toolbar, Layers, Options Bar, …) visible? 

[Chris 486]

You can try a quick fix of flattening all layers before your export by going to Layers > "Flatten Image"

If that does not work, in addition to what @c.pfaffenbichler stated, we'll need more information about your process. What are your steps (with screenshots) to export your file? What format are you tryign to export to, what compression are you setting, what size, etc.

[mglush]

Hi!

What resolution did you build the image? And I agree with Chris's post above that flattening the image before saving to go to print is a really good idea. Did you try his suggestion and how did it work? What format are you saving it to go to print?

Michelle

[EDToShred]

Hi everyone. Thanks for the suggestions. To get this project done in the time I had, I recreated the text design in Illustrator.

I tried merge layers, flatten layer, flatten the whole image etc. They all had the same result. This is a large document. The output was for a banner 7ft wide by 18ft tall. I did it at 150 dpi/ppi? The only other times I had this problem I was working on large documents like this one. That was the reason I came here. I think there is a bug that only happens on large documents. I'm slammed till after the 4th of July. But, I will return and add the screen shots and the info one of the Adobe people asked for. Hopefully, we can get this bug squashed. Thanks for all the suggestions!