OpenType Variable fonts are a good thing, but they do have their hazards. The overlapping strokes is one problem. Not all variable fonts are made that way. Nevertheless it's important to inspect artwork in wireframe view just to be sure. Some OTF Var fonts can be a bit buggy in how well they interpolate their variable instances. Zones like the mid point in a "S" glyph can get marred with little dents. Software updates for fonts is becoming more common to fix issues like that. For some odd reason CorelDRAW has a rough time handling the Helvetica Now Variable font. It can bring an older computer system to a crawl. None of the other variable fonts I have are quite so demanding.The upshot with Variable fonts is they bring back the nifty concepts of the defunct Multiple Master font format and combine them with the vastly expanded character set capability of OpenType. It opens a lot more design flexibility with type.
RoTar said:When I welded, the shapes wouldn't weld correctly. It just left a blank space where the overlapping was.
I believe that all you have to do is weld a second time, without doing anything in between.