I think the relevant part of the doc is % Particularly, a number of broken or ugly design sizes are no % longer used, the look of the bold sans serif typeface at large % sizes is considerably improved, and mismatches between the text % fonts and the corresponding math fonts are avoided. As a side % effect, PostScript and PDF documents may become smaller, because % fewer fonts need to be embedded. So while like any design choice it could be questioned, I think the fact that it does not use all the provided design-size fonts is certainly deliberate. (I assume the above is Walter Schmidt's original documentation text, but I didn't check just now.) David