Thanks Richard you pointed me in the right direction to find this

ß>|{ûöðíá·ï—¿ÿË_~þõw¿üÇ¿ü©_ý¯ÿòw÷Û_þy þáŸÿëïÿáÿ·ßÿå×?þç?üŸþÓ?ÿõ¿þÃûÃ_þ·§‡ÿã—ÿøï_?þw?þîééùóãÛ?

Will load to carrara.

        "id" : "/data/Ravenhair/50sWaitress/50sWApron/50sWApronB.dsf",
        "type" : "figure",
Wont load.

I'll do some further checking to confirm this... Yup, that seems to be the difference. 

This loads

I²„‚ÐïÞßZ¾w¤Û>@—U(‡_Ìí²l™ùŽÿóŸ~óß~úóÿüï?þò·Ÿ~þë¿ýÏ¿ýáåÛóÛË·—~çÿð·¿ýø÷þé¯ú9ÿôþÓo~óÃOì¨úãþþ‡úïù—?ÿø§üÛŸÿãŸþË/ø·

This wont

"id" : "/data/Ravenhair/GenesisMFD/GenMFD/GenMFD.dsf",
        "type" : "figure",

Looking at that I have to wonder how carrara is expected to find something with an incomplete address? Which might explain why resaving fixes it.

And yes, I will point a finger squarely at QA for not testing in carrara.