Documents created from mail merge won't print

Since the document 'prints' to PDF, a faulty printer and/or printer driver is the most likely problem for your 'real' printer. Try uninstalling & re-installing (preferably with the latest drivers from the maker's website).

I can print anything else just fine, so it's not the printer. Can you print the attached file?

It seems to be something to do with the section breaks that the mail merge puts in. If I delete the break, it will print ok, but it also messes up the page layout.

If you look at the file I attached in the original post, you can see this behaviour. Try printing as is and nothing happens. Delete the section break at the end of the document, and the file prints, but the whitespace at the top of the page increases for some reason. Doesn't make much difference in the attached file, but it makes a big difference in the real files I'm working with.

I'm not sure that printing your document would prove much regarding the mailmerge. For starters, it has nothing representing a mailmerge main document or a mailmerge's output (assuming it's supposed to be a letter merge, the Section break on the 2nd page should be a 'Next page' one, but it's a 'Continuous' one instead). The reason your page layout goes awry if the Section break is deleted is because it has a different page layout to the first Section - another indicator that, at best, the mailmerge main document is poorly configured.

They're different because you attachment is not an output document from a mailmerge; if it were, there'd be no change in layout after the Section break - which would only ever be a 'next page' one. Evidently, your mailmerge main document'spage layout isn't the same as the template being used by your 'split' process to produce the individual documents. Furthermore, the fact the output document prints on another user's printer is evidence enough the problem isn't with the document itself.

For a better way to produce individual mailmerge output documents, see Send Mailmerge Output to Individual Files in the Mailmerge Tips and Tricks thread at:
http://www.msofficeforums.com/mail-m...ps-tricks.html
or:
http://windowssecrets.com/forums/sho...ips-amp-Tricks

OK, it didn't occur to me ask whether you had checked the basics - like the print setup, whether there was paper/toner in the printer, etc., etc. Those kinds of things one would expect to have been checked before posting...