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Same here, Designer 1.9.0.932 crashes 5 out of 6 times when I open the printing dialog (CTRL+P). My document has 9 artboards. Printing can be achieved though, as the printing dialog will eventually appear without crashing the app, just restarting Designer and opening the same file several times is kinda annoying, so I'm eager to see that bug squashed.
@Mark Ingram thank you for the good news, looking forward to testing the beta!

Thanks for the report. Just to let you know I've just fixed the issue, and will put the fix into a beta release shortly if you would like to test it out.

Designer 1.7.1
I created a file that clearly shows the amount of inaccuracy after expanding strokes.
I took white icons and grouped them on a black background. I duplicated the group on top of the first one, painted it black, and expanded strokes. The white color of the original, non-expanded icons that is visible, shows the difference between expanded and non-expanded.
Each icon is about 40x40 pixels.
The original afdesign file is attached to this post.
icons.afdesign

Any time schedule on when this might be fixed?

Affinity Designer 1.7.3.481
Bug is reproducible (printed this document on 2 different printers with same results)
The document was created from scratch (basically it's a new document)
Sample document is attached. Photo of the result is attached too.
Operating system is Windows 10 (with all latest updates at the time of writing this)
What happens:
- I created a new document, it's a 2-page template for a small bi-fold wallet
- All Strokes are 2pt thick, all Dashed Strokes are 1.5pt thick
- When I print the document from Affinity Designer, all but 2 objects are printed with a very thin line, including dashed strokes.
The printers that I used to print this are:
- Oki SP 111
- HP Color LaserJet Enterprise flow M880z
Both printers ended up with the same results
Looks like the information about stroke thickness gets lost when Affinity Designer sends info to the printer.

Mini bifold card holder.afdesign

Yeah there's definitely a shift in the line when making the move to expansion. I was expecting a more dramatic result like your image which is why I was confused at first. It's slight, but there's enough that it changes the weight of the line that it appears accurate, but it's not acceptable for achieving any kind of pixel-hinted look. (i.e. professional) I noticed this when working in my own designs and manipulating your file. If it were just a padding issue, would be at least workable, but the paths themselves are being misinterpreted.

Designer is indeed a great software, but it is still not suitable for pixel-perfect work

At the very least, importing IDML files is a must. Scribus and VivaDesigner both do this, and it's the only way to get punters to switch, if they've got legacy documents.

This bug has been reported in Designer 1.6 as far as November 3rd, 2017. Since then, nothing has changed. In this post I even compared different vector drawing software with Affinity Designer (Adobe Illustrator, Corel Draw, and the opensource Inkscape). All perform way better than Designer at expanding strokes... :(

Hi @CJ Randolph, while the scale does make things a little better it is still most certainly not pixel perfect. As you can see in the attached image, which is a 640px x 640px canvas, the red expanded stroke does not line up perfectly with the black original stroke below it. There's seems to be a fundamental issue with the way the software goes about converting strokes to fills.

2019 here, version 1.7 released, bug is still present.
https://forum.affinity.serif.com/index.php?/topic/49241-designer-16-expand-stroke-tool-overly-aggressive-with-rounded-corners/&page=2

Click here to download the latest beta
 
Status: Customer Beta
Purpose: Stability
Requirements: A valid product key, issued when Affinity Designer was purchased.

As this is a beta it is considered to be not suitable for production use. This means that you should not attempt to use it for commercial purposes or for any other activity that you may be adversely affected by the application failing, including the total loss of any documents. 

We hope you enjoy the latest build, and as always, if you've got any problems, please don't hesitate to post here and we'll get back to you as soon as we can. Thanks once again for your continued feedback.

If you have a general question about the software, please head over to the Questions Forum, or if you have any suggestions, please head over to the Feature Requests forum.

Fixes
Updated social media references