MDF (medium density fiberboard) is good for pattern making. You can find it at building supply stores and it comes in thicknesses from 1/4" to 1 1/4". It's fairly cheap and will come perfectly smooth with a router after being cut.
Use a dust mask. It's dirty stuff and not good for your health. I'm allergic to the glue in it.
Also, some people use corian. Durable and easy to work with.
Dave.