Aaah - I think I fought MIME::Lite on that front at one time. If you are on Windows, MIME::Lite does not always know to binmode the file used for an attachment. For .xls files, I now manually patch the mime type to application/vnd.ms-excel, which seems to do what I need, but I have old and disabled code that forced a binary attachment:

    $msg->attach(  
                   Type        => $type,
                   Disposition => 'attachment',
                   Path        => $filename,
                   Filename    => basename($filename),
                   Binmode     => 1,
    );
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If you are not on Windows, or that does not fix the problem, are you sure that the files to be attached have been written completely and their filehandles closed?

Hi, Corion, Thanks for your reply. I'm on Windows, I don't know basename() function, so I changed to absolutely path, but I still got the same result, the pdf file is not correct.

my $filename = "E:/test.pdf";
my $type = "application/pdf";

 $msg->attach(  
                   Type        => $type,
                   Disposition => 'attachment',
                   Path        => $filename,
                   Filename    => $filename,
                   Binmode     => 1,
    ) or die "Error adding PDF: $!\n";
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opps.. it seems very interesting, in that program, the attachment size is always 11.4KB, no matter what file type and what file size...so strange..