>>The easiest way to do this is to create a laser macro that is pre-loaded to the lser printer; I used an older package called FormWorx to create the layout; WordPerfect's (now Corel's) InForms does much the same thing, and has the benefit of being a still sold and supported product. You create the form in the package, and then output it to a file with PCL macro formatting, assigning it a macro ID. Every time the laser is powered on or off (assuming that you make it a permanent macro, temporary macros only stay around until the printer receives a reset code) you need to reload the form macros. Whenever you want to use a particular overlay, you send the escape code for the desired macro direct to the printer (use the ??? command to avoid bad things happening with reinterpretation of printer codes.)
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>By *create the form in the package*, do you really mean creating the form manually? Like creating tables, lines, boxes, the text, etc.? Or can you scan the existing form then use the package to import the scanned image?

We created our forms in the package; since what we were doing were some standardized forms, we created a template and dropped in some text and a logo before exporting out the macro. Doing this made each macro considerably smaller than a pure graphical image, not anywhere near as major an issue now with faster laser rendering engines and more RAM in the printer, but a major issue for us back when we started with 2MB on a Panasonic 4450i laser and 20+ form layouts. You could as easily take a scanned image (probably more easily) of adequate resolution and drop it in as a graphic in both FormWorx and InForms; I believe the current InForms works with TWAIN interface devices.