6 Answers:
How did you create the font extension? Using Jasper Studio, the generated fontfamily configuration file should be something like the following:
<?xml version="1.0" encoding="UTF-8"?>
<fontFamilies>
<fontFamily name="testArial">
<normal>fonts/testArial/arial.ttf</normal>
<bold>fonts/testArial/arialbd.ttf</bold>
<italic>fonts/testArial/ariali.ttf</italic>
<boldItalic>fonts/testArial/arialbi.ttf</boldItalic>
<pdfEncoding>Cp1252</pdfEncoding>
<pdfEmbedded>true</pdfEmbedded>
<exportFonts>
</exportFonts>
</fontFamily>
</fontFamilies>
I just followed the instructions at http://community.jaspersoft.com/wiki/custom-font-font-extension. (I used the three separate font files fronm Windows/fonts, one for each variant. I exported them together.)
But the line
<italic>fonts/Arial_Italic/ariali.ttf</italic>
does look odd with the underscore instead of the hyphen.
I tried again using underscores rather than hyphens, - recreated the extensions, exported, changed to underscores in my jrxml, but still the same error.
Please download "testArial.jar" and use it in your report to run a test - make sure to use font extension name "testArial" in your report field.
This font jar was created in Jasper Studio version 6.1.1 and several of my users had used it as the sample to generate and deploy font extension into their JRS installation successfully.
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Thanks for the tip, but placing the font jar in tomcat/lib made no difference