I've seen this before and worked with some engineers at Apple on
this during a Carbon kitchen. It's been a while, but as I recall
what happens is that beyond a certain point size, the glyphs start
running into precision problems with the math inside of ATS. As I
recall, what I did to fix it, was to always ask for a 1000 pt font
and then scaled the curves to the appropriate size.
Yup, that worked. So did you file a bug for this? If it's been a
while since you worked with Apple engineers on this, one would hope
that it would've been fixed by now.
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