If you are printing your own patterns - use card stock. Almost every printer that I know of has a way to print heavy card stock. I have two printers and both have a small door front and back so that the card stock doesn't have to bend. Works great some printers you can only feed one at a time - but if you are quick - you can feed them as fast as the printer will take them.
I basted my fabric to my shapes and when I got to the corner I folded the fabric carefully and basted that in place as well. I did a whip stitch combining the pieces and when done I pressed it from the front with either Best Press or diluted Starch before removing the basting and paper.