Hi Evan,

I am not mistaken, you now have two objects: the MTDLL, which creates the HTML output to be converted to PDF, and the EXE, which is called from MTDLL and actually invokes the PDF convertion print job? If yes, then try to find out first what instance causes 100% CPU - the MTDLL or the EXE. If this is the MTDLL - you might have a very tight internal loop, which overuse the thread. One of the technique in this case would be to make a Win32 API call to Sleep function to let the OS an opportunity to swicth threads.

Igor.