PROCESS Step 1: Cut Fabric
Roll out fabric along a flat surface. Lay printed paper templates on the top of the fabrics. Carefully cut all the pieces out using either fabric roller blades, scissors or blade; cutting both paper and fabric at the same time. Clip the paper templates to the fabric pieces for later reference.
Step 2: Categorizing Pieces
Arrange the pieces in groups by matching the labelling system. Ensure no pieces are missing. Pieces have a width (short side, joined to make strips) and a length (long side, strips are looped and joined to make the geometry)
Taping
Taping ensures the stitching process is more accurate and convenient. Using 5mm double sided tape, run tape along 10mm from the cutting edge. The middle distance of the seam allowance should now be 30mm.
Step 3: Taping part 1
Tape the internal strip joint side of the clear PVC pieces.
Step 4: Stitching Pieces into Strips
Use a double stitch flat seam with a stitch separation of 10-15mm. The first stitch is run to connect the pieces into strips before second stitch is run to make a double flat seam. After taping, sew pieces into strips by joining the widths of each piece.
Step 5: Taping part 2
Apply double sided tape along the length of the strip. Avoid the Clear PVC sections, as you don’t want the tape to be visible.
Step 6: Joining Strips into Geometry
Join strips one after another, while closing off the loops. The geometry is formed gradually as more strips are stitched to the next. Due to the movement of fabric, patches might be required at the loop joint. As more strips are joined the inflatable becomes heavier, it is suggested at least one extra person is required to help feed the fabric through the sewing machine.
Step 7: Fan Connection
Match the fan diameter to the opening at the fan end (by Geometry Team). Use Velcro to attach the fabric to the fan, by sewing a strip of Velcro to the inside of fabric opening, and by gluing a strip of Velcro to the fan.
Step 8: Entrance
Using the two 1m diameter wooden rings (provided by The Timber Workshop) overlap the rings, secure the fabric in-between and bolt the rings together.
Step 9: Additional Cable Seams
Exterior seam pockets for threading sensor cables through. Cut a 5mm wide white fabric strip to length of seam and hand sew over the existing seam. CHAPTER TITLE 89