It's quite alright, I don't think anyone here completely freehands their patterns. When I build a prop like a sword or a gun out of foam, I first draw a doodle of it on graph paper. Then I use the grid marks to determine how much I want to scale each part up to full size, and use more graph paper (hey, it's cheap) to make the full-size patterns, with a ruler or protractor to help make nice straight lines. If it's a symmetrical piece I can just fold something in half when cutting to make both sides the same. I'll have the entire mockup in paper, overlapping and laid out nicely to make sure it looks good before I trace each piece onto foam and cut! Look at enough tutorials and picture guides and you can see that even the pros have tons of sketch marks on their unfinished patterns and foam where they re-drew something more than once (especially curvy bits) until it was just the right shape. As long as you're not gouging the foam with your pen, all mistakes be covered up by the paint job anyways. Good starter projects are things like shields since they're mostly basic geometric shapes that get you used to working with foam before going all crazy with the details.
Armor is a different beast though since you'll be shaping it to your body. That's where things like the duct tape mannequin come in handy when learning how to make patterns. And 3D shapes are a lot easier to hide flaws like imperfect lines and circles, so long as it still fits decently well.