As a byproduct of designing a number of maze books, I ended up with a lot of tessellation patterns. I used them to design two packages of fonts that are now available on myfonts.com. Tescellations is a set of fonts that are composed of letter forms that tessellate.
Included in the package is one font that lets you easily make letter tessellation patterns. Simply type a bit of text with one character, such as:
AAAAA
AAAAA
AAAAA
then format it with TescellationsPatterns and make sure that the font size and line spacing are set to the same value.
Why stop at letter tessellations? TessieDingie contains two typefaces that allow one to make tessellation patterns. One contains abstract shapes and the other contains shapes that resemble birds, insects, tools, vehicles, and other objects from everyday life.
For more information, follow the links and check them out at myfonts.com.