Digital Fab midterm

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.


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.



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.


The final attempt, as it is drying (and stiffening).

Detail shots in the Picasa album.