That was my only solution too, but there are D10 thru D387 auto generated D-Codes, ALL of them with generic fill width of 10. I can highlight them all at once and change them to 1 or 2 mils (isn't 1 too small, guessing it will make the fill size too big?).
However, is changing them ALL the correct answer? I have no idea which one is causing the problem.
I have never needed to change a generic system generated fill width previously in gerbering about 50 boards. Why now?
Was looking at some old PCBs and their CAM setup, and all of them also auto-generated D-Codes all using the same generic 10 mil fill width. Not sure why this new board all the sudden has an issue with the fill width (this same board did not have this issue a week ago either).
Maybe it can also be related to the number of digits defined in the Photo Plotter Advanced Setup?
I am not sure if the Photo Plotter Advanced Settings is saved in the .pcb file or in system files. Maybe the generic setup in your PADS system has changed?
However - when I used mil settings in PADS I always used 1 mil fill width. Maybe the filesize is increased, but that is not a problem.
Now we have a metric setup in our designs. We now use 0.01mm fill width.
You can just delete all the existing D-codes, set fill width to 1 and the run the Gerber documents.
Thanks Klaus, that seems to have fixed it!