Now that the mystery is solved, why the PDF font size is 11.955 when declaring the documentclass as 12pt (see Why does PDFLaTeX and XeLaTeX generates 11.955 font size for 12pt documentclass option?), I stumbled over the next puzzling thing with PDF font sizes:
When combining Arial and Helvetica in the same .tex file like so:
% !TEX TS-program = xelatex
\documentclass[12pt]{article}
\usepackage{fontspec}
\newfontfamily\myArialFont{Arial} % only works on Win/Mac where Arial is installed
\newfontfamily\myHelveticaFont{Helvetica}
\begin{document}
{\myArialFont This font size its 11.955 in PDF}
{\myHelveticaFont And this one is 11.911 in PDF??}
\end{document}
I am getting two different font sizes in the corresponding PDF code (using xelatex --output-driver="xdvipdfmx -V4 -z0" to compile without PDF compression):
stream
q 1 0 0 1 72 720 cm BT
/F1 11.955 Tf 56.41 -65.75 Td
[<0037004b004c0056>-278<0049005200510057>-277<0056004c005d0048>-278<004c00570056>-278<0014>73<00140011001c00180018>-277<004c0051>-278<003300270029>]TJ
/F2 11.911 Tf 0 -14.45 Td
[<0024>-2<0051>-2<0047>-2<0003>-1<0057>-2<004b>-2<004c0056>-2<0003>-1<0052>-2<0051>-3<0048>-2<0003>-1<004c>-1<0056>-1<0003>-1<0014>70<0014>-1<0011>-1<001c>-2<0014>71<0014>-1<0003>-1<004c>-1<0051>-2<0003>-1<0033>-2<0027>-3<0029>-2<0022>-2<0022>]TJ /F3 11.955 Tf 173.79 -549.94 Td[<0052>]TJ
ET Q
(I've added a few more line breaks into the stream object to make the PDF commands clearer).
One can see that /F1 11.955 Tf (Arial) and /F2 11.911 Tf (Helvetica) are selected with different sizes. Why?
This might be related to the representation of the text in the following PDF array (I am still learning PDF and don't know why the Arial text uses these long hex numbers while the Helvetica text uses the short numbers.)
*************************************************` but that does not seem to be related to the font size issue.
– Linda Sep 19 '14 at 14:40