I am facing the same challenge, and it surprised me that there are so few options to choose from. There are plenty report writers, but usually integrated with some database query tool. Excellent for sales figures and forecasts, but don't you dare to try something else.
I have been thinking about fphp (which produces a pdf from a web page), LaTEX and lately my eye fell on lout (LOUT).
That is a program similar to LaTEX, you have to embed codes between the plain text, and finally the output will be .ps.
Lack of time prevented me to continue reading the manual, but as soon as I arrive at the paper report writing part of my project I am sure I will pick it up again. It looks very promising. I am just not sure yet whether you are able to position boxes & frames exactly thery where you want to have them. But then I read only thru 10% of the manual.
Lout is found at sourgeforge.net. If you try to use it, please share your experiences.