FULL PRODUCT VERSION :
1.5.0_07

EXTRA RELEVANT SYSTEM CONFIGURATION :
HP Laser Jet 4000 PCL6

A DESCRIPTION OF THE PROBLEM :
Printer spool file created is much larger when running under 1.5.0_07 jre then what is created when running under 1.4.3_02 jre

Example: Original text file of 11,430 bytes (sample.txt) when printed:
1.4.2_03 file created is 74,367 bytes
1.5.0_07 file created is 1,578,860 bytes
21 Times larger.


STEPS TO FOLLOW TO REPRODUCE THE PROBLEM :
I have create a test program that reads in an ASCII text file
(sample.txt) and launches our applications print screen.
When the print button is clicked, I choose a typical printer (in my case
- HP Laser Jet 4000 PCL6) that I have configured to print to a file.

I created 2 bat files:

run-spooltest14.bat - runs the test program under 1.4.2_03 and creates
the 74,367 byte file.
run-spooltest15.bat - runs the test program under 1.5.0_07 and creates
the 1,578,860 byte file.


I have also created bat files to compile TextReportScreen.java which has
all the printer specific code.

compile-spooltest14.bat - compiles TextReportScreen.java under 1.4
compile-spooltest15.bat - compiles TextReportScreen.java under 1.5 

EXPECTED VERSUS ACTUAL BEHAVIOR :
EXPECTED -
Generated same file size in 5.0_07
ACTUAL -
1.5.0_07 file created is 1,578,860 bytes
21 Times larger.

ERROR MESSAGES/STACK TRACES THAT OCCUR :
1.5.0_07 file created is 1,578,860 bytes
21 Times larger.

REPRODUCIBILITY :
This bug can be reproduced always.

---------- BEGIN SOURCE ----------
Attached Seperatly
---------- END SOURCE ----------
That test case is too complex.
Here's a simpler one that's more to the point.
All that's needed is to print a Swing text component after setting a physical font
import java.awt.*;
import java.awt.event.*;
import javax.swing.*;
import javax.swing.text.*;
import java.awt.print.*;

public class PrintTextPane implements Printable, ActionListener {

    JTextPane pane;

    public int print(Graphics g, PageFormat pf, int page) throws
                                                        PrinterException {
        if (page > 0) {
            return NO_SUCH_PAGE;
        }
        Graphics2D g2d = (Graphics2D)g;
        System.out.println("BEFORE = " + g2d.getTransform());
        g2d.translate(pf.getImageableX(), pf.getImageableY());
        System.out.println("AFTER = " + g2d.getTransform());
        pane.printAll(g);
        return PAGE_EXISTS;
    }

    public void actionPerformed(ActionEvent e) {
/*
        try {
             pane.print();
         } catch (PrinterException ex) {
               throw new RuntimeException(ex);
         }
*/
         PrinterJob job = PrinterJob.getPrinterJob();
         job.setPrintable(this);
         boolean ok = job.printDialog();
         if (ok) {
             try {
                  job.print();
             } catch (PrinterException ex) {
                   throw new RuntimeException(ex);
             }
         }

    }

    public PrintTextPane(JTextPane f) {
        pane = f;
    }
   static String text = "Twinkle twinkle little star, \n" +
                        "How I wonder what you are.";

    public static void main(String args[]) {
        JFrame f = new JFrame("Print Text Pane");
        f.addWindowListener(new WindowAdapter() {
           public void windowClosing(WindowEvent e) {System.exit(0);}
        });
        JTextPane pane = new JTextPane();
        SimpleAttributeSet aset = new SimpleAttributeSet();
        StyleConstants.setFontFamily(aset, "Courier New");
        //StyleConstants.setFontFamily(aset, "Monospaced");
        pane.setCharacterAttributes(aset, false);
        pane.setText(text);
        f.add("Center", pane);
        JButton printButton = new JButton("Print TextPane");
        printButton.addActionListener(new PrintTextPane(pane));
        f.add("South", printButton);
        f.pack();
        f.setVisible(true);
    }
}