Hi,
>> I tried changing DPI settings to various high numbers (2400, 4800, 9600)
>> under PDF options when I try to export under "DWG to PDF", but it didn't
>> work since the pdf that came out looked the exact same every time.
Hey, assuming you are using _PLOT as you are referring to "PDF options" ... how did you set DPI to 9600 ... that is not available in AutoCAD, the maximum resolution is 4800dpi:

Also please show us a PDF (or better 2 PDF's plotted with different resolutions) and describe what is bad with them.
Simply thinking about 4800dpi it's quite difficult to see that on the screen, even zooming in very close.
Just a few tips when quality in PDF's can look lower than expected:
- in the viewports you are plotting (I assume you are plotting from a layout) make sure you have set the visual style to "2D Wireframe"
- in the plot-dialog make sure that "plot transparency" is disabled.
- try to view your PDF's in different viewers just to make sure it's an issue of plotting and not an issue of your viewer.
And just thoughts...maybe I assume something wrong, but lets see:
>> but since the design is so small (the smallest features are 25 micron circles)
Are you expecting to get a PDF that is later used to print 1:1?
Just to verify that ... 25micrometer = 0.025mm ... if that is the diameter of a circle and you need to plot that with a lineweight so the circle is not filled you need to have a lineweight <= 0.008mm (0.0003 Inch) (and even that will show the circle just as square with 9x9 pixel).
So I assume that is not printed for looking to that PDF with eyes, instead the PDF might be used for some type of production and now you should take care of: a PDF does not store vectors with double precision, the circles you get in the PDF are not at the exact position you have them in CAD-X/Y (based on double precision coordinates) and also not with the (double precision calculated) radius. The coordinates of X/Y and R inside a PDF are based on raster values(pixel), accuracy of double precision is definitely lost and so the quality of your small circles too.
I strongly recommend to transfer such objects in a real cad format, not with PDF to your production.
- alfred -
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Alfred NESWADBA
ISH-Solutions GmbH / Ingenieur Studio HOLLAUS
www.ish-solutions.at ...
blog.ish-solutions.at ...
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CDay 2025------------------------------------------------------------------------------------
(not an Autodesk consultant)