When I open Suitcase Fusion on Mac OS X, I get the error: “Suitcase Fusion could not open the Font Vault at the location: Users/[UserName]/Library/Extensis/Suitcase Fusion/Suitcase Fusion.fontvault".
This error can occur when Suitcase Fusion tries to launch after a power failure or when the computer stops responding. It can also occur after upgrading to a new version of Suitcase Fusion or if your font vault has become damaged.
1) Open /Applications/Utilities/Activity Monitor and type “FMCore” into the Filter search box. If the FMCore process is running, then select it and click the "Quit Process" button. When the confirmation dialog appears, click "Force Quit". If FMCore is not running then simply proceed to the next step.
2) Navigate to: [Macintosh HD]/Users/[UserName]/Library/Preferences/ and remove any files that begin with: com.extensis
NOTE: In OSX 10.10 thru 10.13: In the Finder, hold down the Option key and choose Go > Library to reveal this hidden directory.
3) Navigate to: [Macintosh HD]/Users/[UserName]/Library/Extensis/Suitcase Fusion/ and move: Suitcase Fusion.fontvault to your Desktop.
NOTE: In OSX 10.10 thru 10.13: In the Finder, hold down the Option key and choose Go > Library to reveal this hidden directory
4) Launch Suitcase Fusion from your Dock or Applications folder. You should now have a clean slate; a fresh start; an empty "Font Library" (i.e. fontvault).
5) Are there font sets in your old fontvault you would like to recover?
If NO: Simply add your fonts to the new fontvault by drag and drop into the Suitcase Fusion application window.
1) choose Suitcase Fusion > Preferences > Type Core and press the "Stop FMCore" button to quit the application.
2) Move the Suitcase Fusion.fontvault on your Desktop back to: [Macintosh HD]/Users/[UserName]/Library/Extensis/Suitcase Fusion/
3) Launch Suitcase Fusion. If you are able to get back into your old fontvault, you simply had a bad preference file.
If you receive the same error message about your old fontvault, then the vault is damaged and you will need to re-add your fonts to a new fontvault.
1) Move the damaged Suitcase Fusion.fontvault back to the Desktop.
2) Right-click (or Control-click) on the Suitcase Fusion.fontvault and select “Show Package Contents”.
3) Navigate to the the "SA/l" folder and drag it to the Desktop; this folder contains your fonts.
4) Launch Suitcase Fusion and drag and drop the "l" folder into the Suitcase Fusion application window; the fonts will be re-imported into the new fontvault.
5) You can now remove the old Suitcase Fusion.fontvault.
6) You can now rename the "l" folder, "Backup Fonts" and move them to a backup location.
Learn more about Suitcase Fusion