LyX unable to access needed font resources

Question

I'm getting an error in LyX when I attempt to use certain features that require access to font resources, even though these same features work fine in TexShop.

For example, if I attempt to enable "expert" options for mathdesign, so that I can access small caps, the minimal code that does this works as expected in TexShop, but when I use the same code in LyX, I get an error

!pdfTeX error: pdflatex (file bchrc8a.pfb): cannot open Type 1 font file for reading

unless I remove the "expert" option (in which case I can't get small caps in the running headers in the example).

\documentclass[nohyper,sfsidenotes]{tufte-handout}

\usepackage{fancyhdr}

\usepackage[T1]{fontenc} 
\usepackage[utf8]{inputenc} 
\usepackage[bitstream-charter,expert]{mathdesign}

\title{This is the title and running head}

%As an example, use sans small caps in the running header 
\fancyhead[RE,RO]{\sffamily\smallcaps{\newlinetospace{\plaintitle}}\quad\thepage}

\begin{document}
Body text.
\newpage{}
More body text.
\end{document}

All the files are where they should be, and are up to date, in my MacTeX 2011 installation (and clearly TeXShop is finding them).

---

TeXLive logs the following just before succeeding:

{/usr/local/texlive/2011/texmf-dist/fonts/enc/dvips/ly1/texnansi.enc}
{/usr/local/texlive/2011/texmf-dist/fonts/enc/dvips/base/8r.enc}
</usr/local/texlive/2011/texmf-dist/fonts/type1/bitstrea/charter/bchr8a.pfb>
</usr/local/texlive/2011/texmf-dist/fonts/type1/urw/helvetic/uhvr8a.pfb>

LyX logs the following just before failing:

{/usr/local/texlive/2011/texmf-dist/fonts/enc/dvips/base/8r.enc}
{/usr/local/texlive/2011/texmf-dist/fonts/enc/dvips/ly1/texnansi.enc}
</usr/local/texlive/2011/texmf-dist/fonts/type1/bitstrea/charter/bchb8a.pfb>
</usr/local/texlive/2011/texmf-dist/fonts/type1/bitstrea/charter/bchr8a.pfb>

Answer 1

The expert option requires to buy commercial fonts, as is detailed on page 3 of the documentation of mathdesign.

The discrepancy in behavior between LyX and TeXShop can be explained by the fact that the example you submitted doesn't use Charter small caps because of the \sffamily command in the \fancyhead line that is probably not present in the file you're using with LyX.

The error message indeed points to

!pdfTeX error: pdflatex (file bchrc8a.pfb): cannot open Type 1 font file for reading

and bchrc8a.pfb should exactly be Bitstream Charter Expert. Notice that the log excerpt from the TeXShop run mentions uhvr8a.pfb (Helvetica), that is in fact used for the header.