I have made worksheets for students to trace inside the letters. I have used comic sans font size 48, outline. When I made PDF all the outlined words seemed to bunch together in a small heap in the top left hand side of the page. I tried it with and without embedded print.
If it displays wrong in the print preview it's more likely a problem with the settings in word, as I assume you'll get the same result when printing that to paper. Make sure in the Print dialog you haven't check any options to scale the page down or something that can affect this. If you want i can do a test here with that document, but you'll need to send it to info as mentioned above (you can leave in it the minimum amount of text that still reproduces the problem.