In the first post of this series, I explained the process that I use to make paper patterns for parts. Simply put, output your design to your printer, use the tiling feature to divide larger drawings into printer size pages, splice the pages together, glue it onto MDF or plywood, cut close to the line on a bandsaw and finally, fair the results with rasps and files.
The most important ingredient is the first one: a digital drawing or CAD design. Though the process works well and is basically a no-cost way to making patterns, it does take time. Splicing together the paper, cutting and smoothing out the design and shape add up you have a number of patterns to make. The results can be satisfying, though close, they aren’t quite perfect. As it turns out, with the same drawings and for a reasonable cost, you can take the process one step further and have someone CNC patterns for you.