First, all this has essentially nothing to do with the Adobe FDK for OpenType; you should probably ask in the PostScript forum where you'll meet more experts on printing and how fonts are sent to printers.
But there is something about your question that is confusing to me, and probably would be to people on that forum as well:
A Type 42 font is essentially a TrueType font with a little bit of PostScript wrapped around it for consumption by a PostScript device.
The ".pfa" extension is reserved for the ASCII/Unix flavor of Type 1, which is also how Type 1 fonts are sent to PostScript devices. It's utterly different from a Type 42 font.
So, saying that you converted a .ttf font to a Type 42 font with a .pfa extension is a bit confusing.
OpenType fonts with TrueType outlines (usually .ttf, though technically one could give them a .otf extension) are functionally the same as TrueType fonts, and are best printed to PostScript devices as Type 42 (unless they are mapping to some font built into the device).
Although we're not talking about them, for other folks I'll just mention that OpenType CFF fonts are the ones with Type 1 style outlines. They have a .otf extension, and are sent to a printer by decompressing the CFF font back to a Type 1 font which is sent to the printer. (CFF with Type 2 charstrings is a lossless compaction of Type 1.)
Cheers,
T