How reliable is HTML → PDF in production systems?

I’ve worked on a few projects where generating PDFs from HTML seemed like the obvious solution reuse templates, leverage CSS, render with a headless browser, done.

In practice though, things got messy fast. Page breaks behaving inconsistently, fonts rendering differently across environments, subtle layout shifts between browser engines, performance issues under load.

It works, but it often feels fragile.

I’m exploring this more deeply while working on an HTML-to-PDF feature part of PDFGeneratorAPI and I’m trying to understand whether most teams eventually accept the quirks or move toward a different rendering approach entirely.

For those running this in production, how stable has it been long-term? Any setups that genuinely reduced the “constant fixes” cycle?