As the problem occurs with my brand new PC, I think we can rule out something I have done with my PC.
So that leaves a bug in Word 2010, which was never there in Word 2003.

It seems a problem with Margins, because in the uncommon event the error/crash doesn't occur I get a message:
"The margins of section 1 are set outside the printable area of the page. Do you want to continue?"
I click Yes, and it prints ok.
nb: No "Now printing body" message.

However, when the error does occur, there is no such margins warning, but always
"Now printing body" then
"There is insufficient memory or disk space. Word cannot display the requested font."
Also, if I don't imemdiately close the doc, MS Word 2010 crashes, and the doc can get corrupted.
The only temporary fudge fix is delete the normal.dot, and run Smart Defrag 5... but postpones next error.
Also if I don't do this fudge fix, if I try to open same doc,
"There is not enough memory or disk space to update the display"
... followed usually by MS Word crash.
Any help much appreciated.

Not necessarily. It rather depends on what you copied from your old PC. See
http://www.gmayor.com/what_to_do_when_word_crashes.htm then http://wordmvp.com/FAQs/AppErrors/ProblemsStartingWord.htm

Do you have the correct printer driver for the operating system?

Word 2010 (fully updated) is perhaps the best and most stable Word version that Microsoft has produced. It should not be automatically assumed to be responsible. Most problems are caused by problems with the user files - especially the normal template, which for word 2010 is Normal.dotM

If you have not changed the default location enter or copy
%appdata%\Microsoft\Templates
to the address window of Windows Explorer and you will be taken to the folder that contains the default template. Note that this folder is normally hidden.

An old normal.dot file from an earlier Word version in the folder will cause the new normal template to use settings from that template, especially including macros that may not be compatible with the newer version. If that is the case here, then remove the old template from the folder before allowing Word to build a new one.

Set the Word option (File > Options > Advanced > Save) prompt before saving the the normal template and only save the template when you have a change that you want to retain - including the first time Word is closed after creating the new template.

__________________
Graham Mayor - MS MVP (Word) (2002-2019)
Visit my web site for more programming tips and ready made processes www.gmayor.com

Hi,
I followed instructions on what to do after MS Word 2010 crashes, and also deleting temp files, but I still get the error messages.
Also I was hoping to address the cause of the printing errors (ie failure to print doc), more than the symptoms such as Word crashing.

I also re-downloaded drivers, and still same print errors.
http://support.brother.com/g/b/downl...30cdw_us_eu_as

I also did a dir \normal.dot? /s > f.txt
and it says:
Directory of C:\Users\Sid\AppData\Roaming\Microsoft\Templates
25/06/2017 01:41 PM 20,465 Normal.dotm
1 File(s) 20,465 bytes
so I have no normal.dot, just a single normal.dotm, which I have written a bat file to delete as required.

I also tried last suggestion and still get same print error, but keep getting a message
"Changes have been made that affect the global template normal.dotm. Do you want to save those changes?" so I disabled it.

Also sometimes I get an error when exiting:
"You placed a large amount of data on the clipboard. Do you want this content to be available to other applications after you quit Word?"
This seems consistent with some bug, seemingly related to margins overloading clipboard/memory, as per my previous post.

One of doc's which I commonly use is 188 pages, and ~1.2MB in size. Is that too large for Word 2010? The above clipboard error indicates and I am copying/pasting large amounts which I am not.

You do not want to disable the alert when changes are made. When you deleted the normal.dotm file and then started Word, Word created a new normal.dotm file. That is the change that was made. That should be accepted.
-
As to large amount in the clipboard... That is common when you have copied text or images. You can tell Word to not save.

Your document size is something that should cause no problems in Word 2010 (or 2003 for that matter).

Hi Charles,
I guess I'm not sure what you are asking.
File > Options > Advanced > Save... which of
1) prompt before..
2) always create...
3) copy remotely...
4) allow background...
do I tick?

Also if (1), what do I answer to the pop-up prompt?

Also, re "As to large amount in the clipboard... That is common when you have copied text or images. You can tell Word to not save."
That is the weird part, I get large amount of clipboard and insufficient memory messages when I have not copied any text or images... actually maybe a couple of sentences but nothing to justify being warned about large amount of text on clipboard.