For the most part, I have had no problems with the print function in BIAB. It's not wonderful by any means, but it does work.
This is my workflow. I typically have a 32 bar song which repeats 3 times, almost always with just one set of lyrics, but sometimes with 2 or 3 different verses.
I always start by creating a "linear" version - that is 96 bars with a 4 bar intro. There are no repeats. I get this working first. You can add lyrics as you go, or wait till it's all finished. I use note-based lyrics, but it's probably not relevant.
... There are lots of other tricks to pretty up the final print such as number of bars per line, height adjustment for lyrics and chords, but the key is to develop the song in a linear fashion first. The rest is just decoration.
You make it all sound so simple Dave.

I think the key is what you mentioned.
Start with a linear song not putting in any repeats at all.
Just get it to sound right. Save song and get your .wav/midi files exported.
Then rename song to maybe 'Song-Print' and start messing around with repeats.
As mentioned, BIAB balked at a DC al Fine just because the Fine happened to be at the same place a repeat was!
So don't count on getting all of the repeats or DC's to work properly.
Better to print it out, pencil in the signs that BIAB won't cooperate with and let it be.
Unless you've got a few spare hours with nothing better to do.
