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When I output certain files and then open the Gerber file, all I see when I view it is a square block – no pattern.

I tried your suggestion on a couple of files and it seems to be working. I have a new issue. When I output certain files and then open the Gerber file, all I see when I view it is a square block – no pattern. It doesn’t seem to matter if I output the entire array or single die, I get the same results. See attached zip file. I verified that the data is all poly lines as well as removed the unnecessary hatches and still have not had much luck. Please review and let me know if you can determine the cause.

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Thanks for sending the sample files.  The reason you received a giant filled "rectangle" in the Gerber is because that's what is in the AutoCAD drawing.  

Note:  EasyGerb is just a simple converter (it doesn't have any intelligence or perform any analysis );  EasyGerb will just convert whatever entites are selected.

For example in a Gerber viewer if you turn the fill off, you will see that everything has converted fine; however there are two large "filled" rectangles covering everything. Since EasyGerb has been instructed to fill all closed boundaries, it has filled those rectangles because they were selected.  See my quick tutorial below:

1. Confirm whether you need those large rectangles.
If no, then delete them and the conversion will be fine.

2. If yes, how should they appear in your Gerber?
Are they just reference lines for the manufacturer or any actual boarder?  If yes, I would recommend converting those to Polylines with Width - then EasyGerb will know how to handle those rectangles and assign the proper width (without filling-in entirely). Or explode those rectangles to simple lines and they will not be filled.  Or you can move those rectangles to another layer and then tell EasyGerb to "Not" Fill closed boundaries on those specific layers.

3.  If those Rectangles are required metal in the final design, most likely you will need to place them on separate layers and then use Composite Merge to help instruct EasyGerb how to construct your final design.  Here's a basic tutorial showing how to use EasyGerb to build composite merges:

Using AutoCAD 2014, I make a few simple changes to your Drawing - adding layers for a composite merge.  It may not be the results you want but hopefully it will show the benefits & power of Composite merged layers.  See tutorial below:

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