Resources I used for my bitmap-free font system:
Windows Uniscribe. Let it choose & place the glyphs for you.
The triangle library. Let it mesh the glyphs for you. The above mentioned ttftriangulator might be more viable as I had to add quite some code to deal with curves.
Resolution Independant Curve Rendering Using Programmable Graphics Hardware.
In my experience, distance fields don't have enough precision to support the (admittedly extreme) cases I had to deal with. I am pretty sure building the distance field will take more time than triangle takes to mesh.
Be warned: minification is a real pain. Unless you do proper aliasing, bitmap fonts using freetype will most likely be higher quality (at least as long as you keep reading them orthogonally).