I tried a number of export formats from HFSS and alter the settings in the ACE3000 in different ways, but I cant get a correct conversion with the ACE3000. Like DXF to Gerber, GDSII to DXF, DXF to DXF,
Do you have a specific example and/or experience from your customers that what export format from HFSS should be and what setting in the ACE3000 should be?
Many EDA tools will export their DXF files with all boundaries being individual line segments. Gerber format requires all boundaries to be continuous and closed; so you must let ACE know to connect and Join all line segments. In addition, DXF does not support Islands/holes within boundaries, so you must also tell ACE to detect islands/holes within filled boundaries. I would suggest during DXF import to check the DXF import layer options "FILL", "JOIN". and "DE-EMBED" - also make sure you have told ACE the correct units of your DXF (because DXF does not have a setting which states the units used in your design).