Regarding the drawings after return e-mailing them, you might want to ask your customers if it is their habit to opening the drawing directly from the e-mail or if they save to disk and open. I'm old school and have formed a habit of always opening from a saved to disk file having never trusting an e-mailed copy to work properly due to the e-mail/temporary file mechanism.
Regarding the file size explosion could that be related to some kind of layer filter settings?




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