1. Don't bother with direct font editing. Instead use a vector editor like Inkscape  to save your icons as SVG and then convert them to a complete font-face kit with IcoMoon .
2. IcoMoon will also let you cherry pick icons from a large number of both free and commercial icon packs. This is a great starting point, especially at the sketching phase.
3. A better way to browse icon packs though is with Fontello . Same packs, snappier interface.
4. FontSquirrel font-kit generator is really good, because it does a great job (re-)hinting TTFs so that they come out looking better in smaller sizes (10-14px)
-- but --
The workaround is to serve OTFs. Instead of specifying .eot, .woff, .ttd, .svg in your CSS, list .eot, .otf, .woff, .ttf, .svg. OpenType files are generally heavier, but they also compress better, so it's a wash in terms of a I/O hit if served over gzip'd HTTP.
In other words -
| Make sure to test the hell |
| out of your font-face kits |
So, the testing strategy is to get a proven font-face kit, like Open Sans, and check that both your font and this litmus font render well. If both look aliased, then it's the OS issue. If only yours does, then it's a problem with the font-face kit.
Also, I never had any problems with FontSquirrel.
> I never had any problems with FontSquirrel.
Neither have I. Until 4 days ago :)