I am creating some patterns (in Illustrator) for a client who later uses them in AutoCAD to cut them out by some machine. The problem is that when I export it to .dwg, the files opened in AutoCAD are not acceptable for the client as the points/shapes are misaligned. Illustrator shows exactly the same coordinates for two points, but AutoCAD shows a slight gap between the shapes (see the attached image, and that's just one example).
What DPI settings? What dimension settings in ACAD? What scale? Simply sounds like this is messed up due to how AI always derives its measurments from actual DPI calculations and you are using differtent units on export/ import.
I have ACAD (trial) but I used it only to check the problem that I mentioned. So I don't know what ACAD settings you are talking about, I simply open the exported .dwg and then check for the misaligned points.