Witin QR, other than the Print/Export | Layout options & the <F3> Printer Setup | Printers option, there is no other way to control the size of your fonts when printing to a printer, and virtually no control (within these parameters) for the size of fonts when printing to file.

The fact that you cannot get the proper setup when opening in Word could indicate that your Windows' font size could be to blame - again, this is not a QR problem.

Some things to consider, that may be helpful:
1. Ensure that BOTH your WSM Printer Setup & your QR "Layout" option both use 16cpi/6lpi.
2. Ensure that in Windows' | Control Panel | Display and/or Fonts are set to default to the equivalent of 16cpi. (A common setting for font size is 10 (pixels) Times New Roman (or Arial)for Windows - which I believe is relevant to 14 or 15cpi DOS.) You could adjust to be sure.
3. When I print to file, I make sure the WSM print to file settings is same as the software I am going to use to open the file with, for example, if you are going to open it with Word, your file should have a .doc extension (preferrably) or .txt.

I hope this helps -
Regards,