I think I may have been too pessimistic in my earlier comments about avoiding the dpi problem.
On my Win XP machine I ran my "fonts" program/UI (attached in a
earlier post) at various settings 96 dpi & 120 dpi; each at normal,
large, and extra large fonts. The results are in the attached ZIP file.
It seems that the TrueType fonts (Arial, Tahoma & Courier New) are stable at all settings tested on my PC.
Of the "NI fonts" the problematic ones are some in-between point sizes,
specifically NIDialogMetaFont 11 (There is no NIDialog 11), and
the 13 point (meta) versions of NIMenu and NIMessageBox..
Otherwise NIDialog behaved well, though the steps up in point size were
rather course and uneven (e.g 13, 14 and 15 were the same size).
Older fonts (non-TrueType) such as Courier and MS Sans Serif do seem to
be problematic, so with all due respect to Luis, I think that MS Sans
Serif would not work too well on my PC, even though it is in that
registry key.
Although TrueType fonts seems like the best bet, remember one loses the
integrated look with the OS settings, and including the font in the
distribution kit would probbaly be advisable.
Re changing fonts: There is a better way - see Luis's tip at the end of
this post
Re font mappings:
This may be helpful background; presumably it is not out of date.
Good luck!