This may be a font cache problem. Read this please:
Only use the Adobe Fonts folder:
Have you tried my suggestion from above?
Run this script in Macro window to close all paths:
for g in Font.glyphs:
for l in g.layers:
for p in l.paths:
p.closed = True
- Export without overlap removal, without hinting.
- Export into the Adobe fonts folder (see above).
- In AI, type your text, covert to outlines, and open the paths again by removing the closing segment, probably best with a script again, if you need to do it often.