Well with CREO 5 you have a chance - M010-020 were full of PDF problems but perhaps with later revs they have fixed them.
One answer to your problems is the archaic pen table as suggested by Mahanta. This basically maps screen colours to pen styles - have attached one below. Cut and paste into a text file save as *.PNT and follow Mahanta's suggestions. This one outputs grey hidden lines, everything else is black. Pens are for A3 print so are thickish. As the default screen colours change with each version of ProE the colour designations wont be accurate.
As you can see this only uses 6 pens - students of PTC ancient hieroglyphics may be able to do this in a simpler manner using USE_8_PLOTTER_PENS and PEN(X)_LINE_WEIGHT. However to tailor pen thickness and colour to sheet sizes, PNT and PCF files are the way to go.
! PEN TABLE v1.0 Feb2012
!
! referenced by A3_PDF.PCF
!
! VISIBLE COLORS are the colors seen on the screen - they are user definable in View>Display Settings>System Colors
! and they vary with different versions of ProE. COLOR_NAME is the parameter used in ProE to identify the visible colors.
! DRAWING ENTITIES are the drawing features controlled by the pentable variables.
! PEN SETTING
! VISIBLE COLORS COLOR_NAME DRAWING ENTITY DEFAULT BELOW
! Geometry drawing_color outline geometry,section text/arrows Pen 1 Pen 1
! Hidden Line half_tone_color hidden lines,datum axes/planes Pen 3 Pen 3
! Sketch section_color sketch lines Pen 6 Pen 6
! Curve datum curves
! Quilt quilt_color quilt edges Pen 1 Pen 1
! Manuf Volume magenta_color quilt outlines Pen 1 Pen 1
! Sheet Metal attention_color sheet metal Pen 5 Pen 5
! Datum datum_color hidden lines,datum coords/axes/planes Pen 3 Pen 7
! datum tags
! Letter letter_color dim lines/leaders,gtol frames/leaders, Pen 2 Pen 2
! hatching,threads,balloons & leaders,
! tables,surface finish,detail view boundaries,
! axes & centerlines
! Highlight-Primary highlite_color Pen 4 Pen 4
! Highlight-Secondary dimmed_color tangent edges,section centerline Pen 7 Pen 7
! datum planes, coord x/y/z
! Highlight-Edge edge_highlite_color text-table,balloon,details,note,gtol, Pen 8 Pen 8
! surface finish
!
! The following colors are reserved for specific purposes and apparently shouldnt be reassigned
!
! Preselect Highlight presel_highlight_color Pen 1
! Selected selected_color Pen 4
! Secondary Selected secondary_selected_color Pen 4
! Preview Geometry preview_geom_color Pen 1
! Secondary Preview Geom secondary_preview_color Pen 1
!
! Note
! 1. For this pen table USE_8_PLOTTER_PENS YES (config.pro)
! 2. LINE_STYLE_STANDARD (Drawing Options file) changes text color to the following
! std_ansi - letter_color (detail view boundaries also altered)
! std_iso - edge highlite_color
! std_jis - edge highlite_color
! std_din - edge highlite_color
! so std_ansi restricts letters and leaders to same pen, others allow different pens
! 3. CUTTING_LINE affects line styles
! 4. pen(X)_line_weight (1-16) affects pen width
! 5. User-Defined Colors (on Properties Tabs) are mapped to Pen 1
!
! Pen Color black - color 0.0 0.0 0.0
!
!White entities to plot pen 1 - outline geometry,section text/arrows
pen 1 thickness 0.045 cm;color 0.0 0.0 0.0;drawing_color,quilt_color,magenta_color,presel_highlight_color,preview_geom_color,secondary_preview_color;
!
!Yellow entities to plot with pen 2 (dim lines/leaders,geotol frames,hatching,threads,balloons & leaders,tables)
pen 2 thickness 0.015 cm;color 0.0 0.0 0.0;letter_color;
!
!Grey entities to plot with pen 3 (hidden lines)
pen 3 thickness 0.015 cm;color 0.75 0.75 0.75;half_tone_color;
!
!Dark Red entities to plot with pen 4 (drawing frame)
pen 4 thickness 0.060 cm;color 0.0 0.0 0.0;highlite_color,selected_color,secondary_selected_color;
!
!Dark Green entities to plot with pen 1 (sheet metal)
pen 5 thickness 0.045 cm;color 0.0 0.0 0.0;attention_color;
!
!Cyan entities to plot with pen 6 (sketch lines)
pen 6 thickness 0.020 cm;color 0.0 0.0 0.0;section_color;
!
!Dark Grey entities to plot with pen 7 (tangent edges,section centerline,datum axes/planes)
pen 7 thickness 0.015 cm;color 0.0 0.0 0.0;dimmed_color,datum_color;
!
!Green entities to plot with pen 8 (text, balloon text)
pen 8 thickness 0.030 cm;color 0.0 0.0 0.0;edge_highlite_color;
!
!
!end of pen table
