diff --git a/src/utils/pdf/__tests__/create-document.test.js b/src/utils/pdf/__tests__/create-document.test.js
index f2c656d5..8a09b984 100644
--- a/src/utils/pdf/__tests__/create-document.test.js
+++ b/src/utils/pdf/__tests__/create-document.test.js
@@ -52,4 +52,16 @@ describe('createDocument', () => {
     ).rejects.toThrow('boom');
     expect(onError).toHaveBeenCalled();
   });
+
+  it('calls onError and rejects when the browser download fails', async () => {
+    const { pdfMake } = createFakePdfMake();
+    const onError = jest.fn();
+    global.URL.createObjectURL = jest.fn(() => {
+      throw new Error('no blob url');
+    });
+    jest.spyOn(console, 'error').mockImplementation(() => {});
+    const api = await createDocument({ pdfMake, template: () => ({ content: [] }), data: {}, onError });
+    await expect(api.download('receipt.pdf')).rejects.toThrow('no blob url');
+    expect(onError).toHaveBeenCalledWith(expect.objectContaining({ message: 'no blob url' }));
+  });
 });
diff --git a/src/utils/pdf/__tests__/download-blob.test.js b/src/utils/pdf/__tests__/download-blob.test.js
index 313c4212..1fda36c1 100644
--- a/src/utils/pdf/__tests__/download-blob.test.js
+++ b/src/utils/pdf/__tests__/download-blob.test.js
@@ -39,4 +39,12 @@ describe('downloadBlob', () => {
     downloadBlob(new Blob(['%PDF']), 'file.pdf');
     expect(document.body.contains(anchor)).toBe(true);
   });
+
+  it('rethrows when the browser cannot start the download', () => {
+    global.URL.createObjectURL = jest.fn(() => {
+      throw new Error('no blob url');
+    });
+    jest.spyOn(console, 'error').mockImplementation(() => {});
+    expect(() => downloadBlob(new Blob(['%PDF']), 'file.pdf')).toThrow('no blob url');
+  });
 });
diff --git a/src/utils/pdf/__tests__/resolve-font.test.js b/src/utils/pdf/__tests__/resolve-font.test.js
index 52296213..41354b1c 100644
--- a/src/utils/pdf/__tests__/resolve-font.test.js
+++ b/src/utils/pdf/__tests__/resolve-font.test.js
@@ -25,6 +25,14 @@ describe('resolveFont', () => {
     expect(pdfMake.addFontContainer).toHaveBeenCalledWith({ vfs: font.vfs, fonts: font.fonts });
   });
 
+  it('falls back to Helvetica when a pre-baked container does not define its family', async () => {
+    jest.spyOn(console, 'warn').mockImplementation(() => {});
+    const pdfMake = fakePdfMake();
+    const font = { family: 'Brand', vfs: { 'BrandSans-normal.ttf': 'QUFB' }, fonts: { BrandSans: { normal: 'BrandSans-normal.ttf' } } };
+    await expect(resolveFont(pdfMake, font)).resolves.toBe('Helvetica');
+    expect(pdfMake.addFontContainer).not.toHaveBeenCalled();
+  });
+
   it('fetches + base64s a URL font and registers a container', async () => {
     global.fetch = jest.fn(() => Promise.resolve({ ok: true, arrayBuffer: () => Promise.resolve(new Uint8Array([65, 66, 67]).buffer) }));
     const pdfMake = fakePdfMake();
diff --git a/src/utils/pdf/download-blob.js b/src/utils/pdf/download-blob.js
index 91fb4086..09a44d0d 100644
--- a/src/utils/pdf/download-blob.js
+++ b/src/utils/pdf/download-blob.js
@@ -30,6 +30,7 @@ export const downloadBlob = (blob, filename) => {
   } catch (err) {
     // eslint-disable-next-line no-console
     console.error('[pdf] download failed', err);
+    throw err;
   }
 };
 
diff --git a/src/utils/pdf/resolve-font.js b/src/utils/pdf/resolve-font.js
index df72be72..4390a1b3 100644
--- a/src/utils/pdf/resolve-font.js
+++ b/src/utils/pdf/resolve-font.js
@@ -57,6 +57,11 @@ export const resolveFont = async (pdfMake, font) => {
 
   // Imported / pre-baked container — no fetch.
   if (font.family && font.vfs && font.fonts) {
+    if (!font.fonts[font.family]) {
+      // eslint-disable-next-line no-console
+      console.warn('[pdf] font container lacks family, using Helvetica:', font.family);
+      return HELVETICA;
+    }
     pdfMake.addFontContainer({ vfs: font.vfs, fonts: font.fonts });
     return font.family;
   }