How can I match the line thicknesses in different sizes of the same font?

Question

I'm working on a graphic that includes a handwriting font, and I'd like some text to be larger than others. The obvious issue is that when I make the font larger, the lines also get thicker. Has anyone found a good solution for this problem, other than limiting the design options to large font families with lots of weights? I do employee communications design work for a call center, so purchasing a big font set for internal communications isn't an option.
I've tried to "hide" some of the larger text's thickness by adding a white stroke to it, or by hiding the font edges with a mask, and I've also tried artificially "bolding" or adding a stroke to the smaller text. They all result in noticably distorted text, particularly around corners, and the results are particularly horrible when using something with texture, like a chalkboard font. I haven't had any better luck in Illustrator, either.
I'm sure I'm not the only one out there who wants to simulate the look of one person writing in different sizes with the same writing utensil. Beyond writing it myself (my handwriting is ugly), can you think of any solutions I haven't tried?
Thanks in advance!
Paula

Answer 1

Thanks, I'll try the Min/Max and see if that works any better. The final output in this case is pixel based, for use in PowerPoint and in email headers. I often do my text work in Illustrator, but in this case I was trying to simulate writing on a chalkboard, so I started in Photoshop so I could see how it looked against the background as I worked. I actually face this challenge fairly frequently, though.
The team I design for is virtual, with over 700 people spread across the US and up into Canada. For that reason, I like to use the "hand drawn" look on occasion to bring some warmth and personal touch to the communications, to contrast with all the super-polished "high gloss" graphics they look at all day in their work tools. It's a real challenge to find text and artwork that matches well once scaled to fit my documents, especially since most of the vector-based artwork I find online has already been converted to outlines, so it doesn't retain the same stroke thickness when the images are scaled.
If anyone out there knows of an illustrator who doesn't convert their sketch-style graphics or fonts/typography to outlines before putting it up for use, either on Shutterstock or on any free site (since those are the ones I can use) I'd love to hear about it!