Merging with Calypso pdf, Ghostscript

[[Ch...]]

I have a weird frustrating issue with GearPro, want to see if anyone else if seeing the same thing.  

For years I've stitched my GearPro reports to the end of my Calypso reports using PDF all (using GhostScript) save in Calypso.   Never had any issues with it.  

Recently, I've had a couple of programs that are failing to stitch together.  Its saving just the Calypso reports.  Even more frustrating, its not entirely repeatable.  It seems to happen more often on all tooth scans (reports are larger maybe causing issue?).  Also, if I restart Calypso and GearPro it will almost always correctly stitch the first one just find, but subsequent runs may not stitch. 

 

I know this isn't necessarily a GearPro issue, but has anyone seen this before?