I dusted off some decades-old tech and developed a postscript solution meeting the specs and fitting on a US letter page. Most of the strokes are about 5/16", none that I saw under 9/32". The sample below actually has three separate numbers: 3946, 0125, and 7844.
These were chosen based on my team's number, including all ten digits, and the fact that "4" is the widest digit. Just use one of the blocks of code and replace the appropriate four digits with your team number. (1, 2, and 3 digit teams can delete one or more of the first three digit lines):
Code:
%!PS-Adobe
20 setlinewidth 0 setgray
/Helvetica findfont 350 scalefont setfont
/showchar {currentpoint 2 index false charpath stroke
moveto true charpath fill} def
90 rotate 0 -500 translate
0.75 1 scale
27 setlinewidth 1 setlinejoin
130 108 moveto (3) showchar
330 108 moveto (9) showchar
540 108 moveto (4) showchar
750 108 moveto (6) showchar showpage
90 rotate 0 -500 translate
0.75 1 scale
27 setlinewidth 1 setlinejoin
120 108 moveto (0) showchar
330 108 moveto (1) showchar
540 108 moveto (2) showchar
750 108 moveto (5) showchar showpage
90 rotate 0 -500 translate
0.75 1 scale
27 setlinewidth 1 setlinejoin
120 108 moveto (7) showchar
330 108 moveto (8) showchar
540 108 moveto (4) showchar
750 108 moveto (4) showchar showpage
If you have linux, you can use it pretty directly. If you have windows, you'll have to get ghostscript and ghostview (gs and gsview). I'm attaching PDFs of my sample file so those with windows can preview it.