In a nutshell, I'd like a given plotter (e.g. our TDS700) to produce identical plots from the same AutoCAD source file (e.g. a 24x36 layout), whether 1.) plotting directly to the plotter from AutoCAD, 2.) printing DWF output from the included DWF6 ePlot.pc3 file, or 3.) printing PDF output from the included DWG To PDF.pc3 file.
All other things being equal (or at least starting out the same among all of the other plot settings, including .ctb, centering the plot, and no scaling of lineweights), the direct plot and the print of the DWF output essentially appear identical. However, the PDF (both on screen and in print) comes out heavier and is vertically off-center upwards almost a quarter-inch.
While we'd like all of our clients to accept DWFs, we still need to provide PDFs to some. Any thoughts on where to begin to tweak the DWG To PDF.pc3 file to get its output to be consistent with the other two?
2008's PDF driver is weak: find an alternative external PDF driver (many freebies around) and get better results. AutoCAD's PDF drivers improved vastly starting in R2010.
And you can get close and there is no true matching of output between paper and electronic file: they are not quite the same thing and too many variables in play to give you consistent results.