This seems a rather lengthy but fun way of making fonts - handwriting your own font.

Otherwise there's the digital method

And regarding bobby12's comment on needing a patent, that's just not true. Just make your font and submit it to all the free font sites out there!

However, bobby12 is correct in saying that it would not be an appropriate font to use for the web, since most (if not all) users will not have the font installed.