Render the report in .NET Framework and export it directly from code, without opening the viewer.

Merging documents. Enable cache mode, then collect the pages of each loaded document into one report before exporting:
var report = new StiReport();
report.ReportCacheMode = StiReportCacheMode.On;
report.RenderedPages.CanUseCacheMode = true;
report.RenderedPages.Clear();

var tempReport = new StiReport();
for (int index = 0; index < 30; index++)
{
    tempReport.LoadDocument(stream);
    foreach (StiPage page in tempReport.RenderedPages)
    {
        page.Report = tempReport;
        report.RenderedPages.Add(page);
    }
}

report.ExportDocument(StiExportFormat.Pdf, "Result.pdf");
Cache mode keeps memory usage under control while a large number of pages is accumulated, making it possible to build a single big PDF from many source documents.

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