I believe I know a possible cause. I have noticed that the font size changes according to the windows desktop icon font size. I know this sounds wierd, but I believe LabVIEW uses this windows font to automatically size its fonts. If you have 18pt desktop icon font on your development machine, many LabVIEW fonts are associated by default with this size, so when they go to the target machine whose icon font might be 12 they appear huge.