I’ve been happily using KiCad for a long time. Since I use toner transfer method for making PCBs at home, it was a breeze to hit “print” in pcbnew and get a high-quality result.
Lately I’m using bleeding-edge KiCad (built from the very latest source available at Launchpad) and the “Print” output is horrible. I can reliably manufacture 10-mil trace/space, but printing 10-mil trace/space now gives overlapping/merged traces, pads with drill hits that are misaligned, not to mention text output (if I include a silkscreen layer, or the page frame) looks just awful.
By comparison, if I use the “Plot” function and plot to PDF, I can then print that PDF and it’s pristine.
I’m on the development mailing list, but before I bother them with this, I thought I’d pose the question here in case anyone else has some insight.