I love graphic design, what a fun way to combine math and creativity. I use Adobe Illustrator to design decals. You can find the template for minifig size decals at the Minifig Customization network webpage or Google 'minifig template'. This is a starting point. Place this jpg into AI. Then trace over the jpg to create lines you can edit. I use layers in AI so that the cut line used by the plotter (die cut machine) is on a separate layer, and won't be moved while editing the graphic layer.
If you are just printing on sticker paper and cutting by hand, you want to design just to the size you want to cut out. If you use a plotter, design so that there is some extra detail outside of the area to be cut so that if the plotter is out of register slightly, you don't have a nasty white line show up.
You can find lists of Lego colors converted to CMYK values online. This is a start, every printer is different so they may need to be adjusted.
As far as design goes, the sky is the limit. Begin by finding other Lego designs you like and copy them, make changes and go from there. When you have advanced - take a real image and attempt to design it in Lego graphics. This is tricky. Sometimes I make a sketch on paper first.
The more designs you make the easier it becomes, not only do your skills improve but you begin to build a library of elements to pull from. For example: designing Aurra Sing I liked the belt from the Cobra soldier, then pulled the shirt from Padme, then the back from a Jango, added and tweaked a few things and wallah! Couldn't be easier.
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