Steve:
Are you putting the name field in the header section and selecting it from the drop down menu. If you are typing it double check that that it is formatted as the drop down shows it. Does it show up when you are in the edit mode and click on Preview? If it does then save the template and try again. If it does not show up in preview - delete the field save the template. Re-open for edit and put your cursor where you want the field and using the drop down menu select the field you want to use. Click on preview and it should show up. Then Save the file and exit. One other thing that happened to me was that the name field on the first tab of the invoice was blank for a particular invoice and for the life of me I couldn't figure why the email wasn't picking up the name. So just make sure the one you have been using for testing has a completed name field in the BUYER tab. I know these are simplistic suggestions and you may have tried them all. I thought maybe you may have missed one of them. Hope there is some help here for you.

Garry