The individual characters must be saved in one directory with the keyplot naming for each file. I would then expect that they must have both print only fills and a cutpath in each character to be recognized as suitable for the Edge Font selection under styles in Font Designer and that the Gerber Edge Font will not be grayed out.
What I am experiencing, however, in testing this out is that nothing I do will cause the Gerber Edge Font check box to not be greyed out. Further, the help files for both Omega and specifically for Font Designer do not address what may be happening or provide a step by step set of directions for creating an Edge font.
I would suggest that you wait for a reply from Tony Teveris or Dana Goodale, both with Gerber, and who should know what the correct procedures are.