Thanks for the replies. I moved the number to the same layer as the other elements, even though the image won't be exported to PSD. The numbers were converted to shapes, so it's odd that it didn't export.
I looked at the Properties on the PDF and it doesn't indicate which Illustrator version the printer used to export the PDF; all it indicates is that it's an Adobe Acrobat document. In mid July I asked the printer, "How do you create images for printing?" His response was, "We will take whatever files you send, create templates in Illustrator and then save them as .pdf files."
It sounds to me like you were actually able to open the .xar file in Illustrator, or was it the PDF file that you opened in Illustrator? I'm attaching the PNG image. Could you test opening it in Illustrator and then exporting it to PDF, just as the printer did? If you get the rectangles instead of the starburst effect, then I don't know what to do. I'm sitting here wondering what's the point of having special effects if you can't use them. I don't know how else to duplicate that "starburst" look. It's very subtle, but it keeps it from looking like an ordinary flat fill.
If the printer will take PDF files, then I guess the problem is solved, at least as far as some of my cards are concerned. But still I'd like to know what's causing the diamond fill effect to deteriorate.
TIA
Edit to add: I exported the PNG to PDF. Looks just like I want it to. Then I imported that PDF into Xara and exported it to PDF format. So it's a PDF from a PDF. I printed it. Result: no rectangles, but now the colors are off; the fill is more brown, looks dull, and the ring around the white center has too much magenta. You can't really see what I mean in the attached PDF until it's printed.
So if I give PDFs to the printer, does that mean I have to re-do all the colors to get the brightness level back in the colors? (It took a long time and a lot of effort and experimentation to get the colors just right.) Do I just forsake the diamond fill effect for now, settle for something I don't want, and buy/learn Illustrator for future projects? It seems that's where things are headed. I'm 3 weeks away from deadline and very discouraged.
Advice, anyone?
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