Fontsize not affecting some bbm symbols
The bbm
package uses a font that's only available as bitmap. The related .fd
file contains
\DeclareFontShape{U}{bbm}{m}{n}
{ <5> <6> <7> <8> <9> <10> <12> gen * bbm
<10.95> bbm10%
<14.4> bbm12%
<17.28><20.74><24.88> bbm17}{}
and other similar parts. This means that the font is not available at sizes beyond 25pt (24.88pt, to be precise). Indeed, you get the warnings
LaTeX Font Warning: Font shape `U/bbm/m/n' in size <50> not available
(Font) size <24.88> substituted on input line 6.
LaTeX Font Warning: Font shape `U/bbm/m/n' in size <34.99985> not available
(Font) size <24.88> substituted on input line 6.
LaTeX Font Warning: Size substitutions with differences
(Font) up to 25.12pt have occurred.
Solutions? Use a different font that's fully scalable, for instance STIX.
\documentclass[border=10]{standalone}
\usepackage{lmodern,amsmath,amssymb,bm,physics,nicefrac,fixcmex}
\DeclareFontEncoding{LS1}{}{}
\DeclareFontSubstitution{LS1}{stix}{m}{n}
\newcommand{\bbone}{\text{\usefont{LS1}{stixbb}{m}{n}1}}
\begin{document}
{\fontsize{50}{62.5}{\rmfamily
$\displaystyle\int_\mathbb{R}^{} \sqrt{\dfrac{1}{\sqrt{2\pi\sigma}}
\exp(-\dfrac{x^2}{2\sigma^2})}\bbone_{\{x>0\}} \dd{x} = 1 $}}
\end{document}