I've used the free lemoyne star pattern to make a bag (see personal Pictures) and thoroughly enjoyed using it. I very heavily starched my fabric (allow the starch to soak into the fabric for a few minutes before pressing and repeat 2 or 3 times to achieve stiffness comparable to paper/card) and sent it through my printer without paper backing. Don't cut your fabric longer than approx 11 inches and only put through one sheet at a time (don't stack them up)
On the matter of sizes, with some fiddling about with the scaling on your printer you should be able to create any size you want, although the 1/4 inch seam allowance will no longer be accurate. Last years BOM we had to be careful to have 'no scaling' on our printers or the paper piecing sheets came out the wrong size, therefore why not use something that can mess you up, in reverse, to help you out
yours in the cause
Rosemary