Look at this! Thanks to How About Orange, I learned that Digitprop has designed a printable, 3D alphabet that is completely free! Just download the file, print on cardstock, trim with fine scissors like a pair of Cutter Bees and then fold into shape. Each of the 26 characters is a person, animal, or object whose name starts with that letter. I know my kids would have fun cutting out and assembling the alphabet, and then of course playing with the pieces.
Image credit: Digitprop