AutoCad 3D :: Solid Loosing Fillets During PDF Export

I'm using AutoCAD 2010 32bit on Windows XP with built-in video - so no hardware rendering, etc. I have a situation where a 3D solid that I have created looses its fillets while creating a PDF.

The solid was built using Union, Subtraction, Slicing and Fillet operations. I have attached the DWG and two PDFs - one with fillets, the other without. Both PDFs were created within moments of each other from the same DWG. Notice in the DWG that the solid model has now lost all the fillets on the edges, but they were there when the good PDF was generated. I create the PDFs using ACAD's Output | Export PDF feature on a single Layout in Paperspace. When the PDF is generating, for about two seconds you see the solid edges loose their fillets, and then sometimes return to normal, but other times the DWG changes and I have to add the fillets again.

I know about using the Print option, and also 3rd PDF generators but they also fail - plus, I want to use Output because it's more convenient. I like AutoCAD, but I am thinking of dumping it for SolidWorks (which I just evaluated for 30 days). I can't be putting a lot of time into models that loose their fillets. This same issue happened to me about a year ago, and I finally had to re-create the model from scratch to solve. It's ridiculous that this doesn't work, it's kinda fundamental.

BTW: I tried a fresh OS and ACAD install and the problem persists.