HP OfficeJet 7610: printed documents are scaled - can't print exact sizes

[3rdOrder]

I need to print CD inlays, which obviously need to be exactly the correct size. I am finding that everything is coming out significantly smaller than it should. For example, the back panel of the CD is 138mm wide (set precisely using the object properties box), but the printed size is 125mm - very significantly smaller.

I've tested from Word 2007, CorelDraw X6 and Adobe Reader with consistent results. The fact that this template prints at the wrong size suggests it's a printer not an application problem http://www.maxduplication.co.uk/content/files/JewlBox_Inlay.pdf.

I've been through the printer settings and everything seems fine - no "scaling" or "print to fit" options are selected. I'm on the most current driver (29.1).

[Bob_Headrick · Accepted solution]

I do not have an Officejet 7610 to test but I did manage to duplicate your results with an Officejet 8600 Plus, running with Letter sized paper and the Officejet 7610 driver.

I printed once with two sided printing turned off.  This properly printed at 118mm x  138mm.  I repeated the process, this time selecting two sided printing, flip on long edge.  This case exhibited the issue you are seeing - the result was printed 107mm x 125mm.  This is likely due to the printer needing a larger top/bottom margin to properly handle duplex printing.  To preserve the page layout the driver automatically shrinks the page, when printing automatic duplexed, even though this does not appear in the driver settings as an option.

I believe the issue will be resolved if you change the printer settings to "Print on both sides:  None".

[3rdOrder]

You are right - turning off duplexing results in prints that are pretty close to the right size. The PDF I linked to in my original post comes out 2-3mm small on the 138mm panel but I can live with that. Thanks.