I created an app a while back to create heroes for Descent that would enforce the official policy laid out by FFG. I sent an email to FFG to see if they wanted to host it for people to use but I didn't hear back. You just enter the information you want and then save the card and it will print out at the correct size. I have used this to make my own heroes and it works great. If anyone thinks this would be useful I can see if I can find some place to host it.
Here is a screenshot (in case the image doesn't show up, here is a link img215.imageshack.us/i/descentherocreator.jpg/):