I print a hexie template on cardstock weight paper, then cut them out with a quilt ruler and a rotary cutter with an old (but good) blade (the template I use is available for free from Texasfreckles.com). I don't cut my fabric in hexagon shapes as that is just too much work for me... I just cut them in squares, then baste around the cardstock cutouts. I just baste through the fabric at each corner of the hexagon, and not through the paper itself. I'm making 1 1/2" hexies and cut my fabric in 2 1/2" squares. I generally sew them together when I have enough to do an individual flower, but if I feel like basting extras I'll do that instead.