Just to clarify - in previous versions of the software, pads were always printed as rectangles. However, as of 0.6.2 we made some changes so that very small pads will be printed as lines. See below:
This change results in a dramatic improvement when printing fine pitch components since it decreases the chances of shorting. However there is still one more issue, if you have thin lines going into traces you will still get lines being double printed like so:
If you look carefully, you'll notice that the 'pads' and the traces are at a slight offset from each other. The traces will be printed on top of the pads. This would result in more ink dispensed and potential shorts.
The ideal solution is to merge the two lines so that the pads look like the footprint @a2retro designed. We already have plans to add this feature, but it is not exactly trivial so I can't say when it will be completed.
Looks like default forum permissions only allowed images. I've changed it to accept Gerbers as well.
By the way, @emcniece - I loved the 'action' shots in the youtube video.