My client Kresta had some leftover fabric from her nursery bedding, and I thought I could make her a custom 3D decorative fabric letter for her baby's room from the scraps, inspired by these letters from Anthropologie. Here is how I made the above letter "G."
First, I chose the sans serif font Arial and printed it in 10% gray scale. I played around with enlarging it, and when it got too big for my printer, I cut up pieces of the enlargement and transferred it onto poster board with the help of my French curve ruler. Below is my posterboard pattern.