Thanks for the help here. It was both of these issues.
Really frustrating that the setting defaults to Low... every single time you make a viewport.
Between needing to fight the multiple resolution settings (viewport, camera, publish), and then the rendering detail which is buried in unintuitive locations... and then now learning that section viewports get their very own different render setting... and of course the service pack bug....
This is a bit much. There are too many settings buried and hidden away that affect something simple like getting a circle to look like a circle and not a polygon... or to get a print ready image instead of a 72dpi mess.
Meanwhile right on the oip for the viewport there is a pulldown called "detail level" which as far as I can tell... doesn't do anything. Certainly it doesn't do enough to justify it's prominent and intuitive place in the top level of the OIP.
I'm not a new user to this program, but I've only started trying to push it's limits in the last couple of years... and I have to say the constant bugs and unintuitive settings buried across the platform is wearing thin. I've had too many anxiety attacks in the last few years when under deadline and V-Works decides that a nice hig- quality sheet layer is something I'll have to work overtime for.