Re: DXP2oo4 and apertures
There are two kinds of apertures - draw and flash. Both are legitimate types of apertures.
A draw aperture is what you saw made up of 5mil lines. Draw apertures use short segments of lines to fill in a shape such as a rectangle, octagonal pads, etc.
A flash aperture is defined as a solid shape. This is what you saw when you rotated the pad to a 90deg position.
There is nothing wrong with your Gerber files - you have an ignorant manufacturer. His CAM software can't properly interpret the Pr0tel D-Codes. Instead of trying to fix his problem, he dumped the files back to you.
D-Code tables are different from one EDA program to another. The PCB fabricator has to understand what format he is working with, and make sure that he reads the data into his CAM software properly.
You have two options.
1-Find a better PCB fab.
2-Read your Gerber files into a third party Gerber editor, such as CAM35O or GERBT00L and write them back in a format your existing fab knows how to use.
I recommend you find a more competent PCB fab.
The 5mil draw cannot be changed withoud degrading the quality of the pad. The size of the line is determined by the size of the pad, and the resolution you specify in the "match tolerance" option of the Gerber setup window. The equipment your PCB fab is using must be antique if they can't handle 5mil lines - most fabs I have dealt with can handle D-CODE lines down to 1mil. Remember that these lines aren't actually put on the circuit board, they are only used to expose film or a mask to make the circuit board. It's like filling in a box by scribling a fine pencil line inside the outline.