My digital fabrication midterm was to create a simple shape (the 'hat') using the CNC and any other digital tools necessary. Our group was assigned textiles, and through a strange shift of focus, developed our shape from leather.
It was a really interesting process, with one spectacular failure and one mostly successful attempt.
PROCESS:
1. Lasercut the 5 leather pieces (smelled HORRIBLE!) including holes and tabs for stitch variation
2. CNC the wooded form from 3/4" plywood
3. Handstitch the leather pieces together to create the rough form
4. Stretch and pin it over the wooden form
5. Soak entire thing in < 200 degree F water for several hours
6. Once dry, the leather can be removed from the wooden form. It retains its shape and stiffness.
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Our first attempt at boil forming failed. Having heard from leatherworkers that you could soak and then stretch the fabric, we let the leather soak in a pan of water inside a warm oven for over 2 hours. Unfortunately, the water was too hot, the leather floated to the surface and baked for nearly two hours, and distorted as it shrank.
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Both forms were made from 5 pieces of lasercut leather. The second form (here) used 4 different stitch types. Unsure about how the stitching would react, we wanted to test a variety.
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The final attempt, as it is drying (and stiffening).
Detail shots in the
Picasa album.