Yeah, I've been a Senior Advisor with Applecare, with Apple 15 years, and lead genius before that and I've seen this pesky issue with the right margin of PDF's (even PDF files with no relevant association to any printer) do this right margin truncation when an email message is saved as a PDF. I just got a new Mac mini M2, did a clean install, no printer associated yet and if I do nothing but save the email receipt Apple sent me for the Mac mini. It looks fine in the email but if you save it as a PDF it truncates some of the right margin. So it's not some setting or setup config issue with the computer. It's some fundamental issue with PDF's exported from Apple Mail. I've tried everything and I've seen it happen so much I tend to just do a screen shot of the text in the email to get everything to show up on the page.
I can't say for sure if it's every email message I export to PDF (actually just checked nope not every email does it so something related to formatting of the received email message I suppose).
In any case it DOES appear to be something to do with the formatting of the actual content in the email message. THEORY: The message is assembled on the fly with some imbedded HMTL or XML code that is doing something weird for the right margin. I say this because I think it's more prominent when what's saved is a email that was formatted and exported automatically by some backend system. What shows in the message itself looks fine but the PDF get's that truncated right margin thing.
Oh, and I just printed another email from Apple for my new iPhone 15 order out as a PDF and also from a printer connected to my old iMac and BOTH have truncated right margins. In essence only what shows up in the email message itself is a faithful rendering of the message.
So I used another receipt email but this one from Audible that saves to PDF and prints fine with no truncation and then compared the raw message code from the Apple receipt and the Audible receipt and discovered that the Apple content includes a string at the end of the lines being truncated of =20 at the end of the truncated lines of text which translates to a control character of 20/n
UPDATE: So on further investigation I've come to the conclusion that this issue has less to do with how the message is saved but how it was formatted by the sender (see below message sent to AskDifferent)
Some Apple mail client email messages truncate 1 to 2 characters on the right of the message when printed or saved as a PDF. Have tested from a Mac with a printer setup and a Mac that has never had an associated printer with equal results. Playing with printer settings has no effect. Suspect the issue is related to invisible formatting in the raw content of the email message. Issue is more likely to be seen when the email content is generated vs sent from a person. For instance the issue is common for receipts generated by online stores.
I've compared the raw email text content of two different generated email messages (one from Apple and one from Audible) where viewing both receipts in email look fine but the printed / PDF output of the Apple receipt looses 1 to 2 characters from the ends of lines approaching the right margin and the Audible receipt looks fine with no missing content in the PDF or printed version. The possible significant difference may be invisible formatting code inside the received message since the Apple email does have embedded control characters (ie. =20 or 20/n) at the ends of the problem lines and the Audible does not.
Can anyone tell me if this issue (in general) is just one of those things NOT related to how I'm set up to receive email, print email, or save email as a PDF but solely dependent on how the message is formatted?
I've spent a good deal of time trying to fix this issue and have come to the conclusion that, in cases where I can't get a faithful version of the email content printed or saved as a PDF, I need to just do a screen print and move on. I've seen this question come up in the Apple user community online but with no helpful answers or even explanations.
I'll report back if I get any answers that might be useful.