Sorry, I should add to that, the troublesome form has not been fully published to Org Library, it has been published using 'publish form as' to a central location.

The person who actually publishes to Org Library just get's a blank email when openning the form. She has a new PC, previously she would publish forms off her laptop.

I strongly believe an Outlook setting/registry key needs adjusting here, as she could view the forms in design normally before switching to new PC.
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-- 'Cool threads, cool threads man.' - lecturer on process handling --