In reply to How many bezier points should be used:
1) Right. Few type designers work directly in TT curves, at least during the design and drawing stages.
2) What do you mean by "lumpy"? The conversion is usually fairly faithful, but conversion from PS outlines to TT outlines usually adds some extra points to the outline and this can sometimes lead to less than faithful conversion. It's typically best to increase the UPM of the font to 2000 or 2048 before converting to TT outlines for this reason.
3) I do both. I would prefer to just do .otf, but some customers prefer .ttf.
