I have fixed this in my matplotlib source, but it's not a pretty fix. However, if you, like me, are very particular about how the graph looks, it's worth it.
The issue seems to be in the rendering backends; they each get the correct values for linewidth, font size, etc., but that comes out slightly larger when rendered as a PDF or PNG than when rendered with show().
I added a few lines to the source for PNG generation, in the file matplotlib/backends/backend_agg.py. You could make similar changes for each backend you use, or find a way to make a more clever change in a single location ;)
Added to my matplotlib/backends/backend_agg.py file:
# The top of the file, added lines 42 - 44
42 # @warning: CHANGED FROM SOURCE to draw thinner lines
43 PATH_SCALAR = .8
44 FONT_SCALAR = .95
# In the draw_markers method, added lines 90 - 91
89 def draw_markers(self, *kl, **kw):
90 # @warning: CHANGED FROM SOURCE to draw thinner lines
91 kl[0].set_linewidth(kl[0].get_linewidth()*PATH_SCALAR)
92 return self._renderer.draw_markers(*kl, **kw)
# At the bottom of the draw_path method, added lines 131 - 132:
130 else:
131 # @warning: CHANGED FROM SOURCE to draw thinner lines
132 gc.set_linewidth(gc.get_linewidth()*PATH_SCALAR)
133 self._renderer.draw_path(gc, path, transform, rgbFace)
# At the bottom of the _get_agg_font method, added line 242 and the *FONT_SCALAR
241 font.clear()
242 # @warning: CHANGED FROM SOURCE to draw thinner lines
243 size = prop.get_size_in_points()*FONT_SCALAR
244 font.set_size(size, self.dpi)
So that suits my needs for now, but, depending on what you're doing, you may want to implement similar changes in other methods. Or find a better way to do the same without so many line changes!
Update: After posting an issue to the matplotlib project at Github, I was able to track down the source of my problem: I had changed the figure.dpi setting in the matplotlibrc file. If that value is different than the default, my savefig() images come out different, even if I set the savefig dpi to be the same as the figure dpi. So, instead of changing the source as above, I just kept the figure.dpi setting as the default 80, and was able to generate images with savefig() that looked like images from show().
Leon, had you also changed that setting?