> I'm having trouble converting the gerber code ( copper and component layers ) > where the gcam software just dies in the KiCad code. Similar sized card with > Eagle goes ok but there is a difference with the gerber code from KiCad.
I suppose you're doing milling isolation and not photo processing, then. I never had trouble with kicad gerbers, I'd think about a bug in gcam... If you can you could eventually submit a bug report for pcbnew with the failing gerber to let us look at it, to see if it's defective.