New sewing techniques: Sewing the round bits prototype 48

48a

This picture shows how little cuts were made and fold over to then sew them with a sewing machine.

Elements of experience:

Positive expected: easier to fold over

 Positive unexpected:

Negative expected:

Negative unexpected: hard to sew, is difficult to not see the cuts that are made

Time: 10min

48b

When it was difficult to hold the cut flaps when being sewed, the idea came to first glue the pieces on the inside so that it is easier to sew.

Because it stayed in place, it was directly sewed upon the elastic part.

This came with the problem that there was a gab, because it was sewed to far from the edge. Of course if it was sewed this way it would always have a little gab where filth can accumulate.

Elements of experience:

Positive expected: more beautiful finish

 Positive unexpected:

Negative expected:

Negative unexpected: gap between the two fabrics, see picture

Time: 15min

48C

The problem with 48b was solved when an extra stitching was applied

Elements of experience:

Positive expected: problem with gap solved

 Positive unexpected: a fun finishing feature

Negative expected:

Negative unexpected:

Time: 2min

48d

After seeing the fun aspect of sewing with zigzag pattern. It was used to attach the top of the casing.

Elements of experience:

Positive expected: no need in using an extra stitching

 Positive unexpected: maybe isn’t needed to bend the fabric in first place because this stitching covers the edge of the fabric so that it can’t fripper

Negative expected:

Negative unexpected:

Time: 10min

48e

The other side of the prototype is completely made of the technique used in 48d

Elements of experience:

Positive expected: faster and easier to make

 Positive unexpected:

Negative expected:

Negative unexpected:

Time: 15min 

Making the filling

The first filling was made with the measures of the knee from Mindy. This was made by pushing her knee into plasticine

Then from that a hard cast is made that is put in a mold to make a new cast from silicone

When it is dry, we get it out of the mold and just have some edges cut away

Elements of experience:

Positive expected:

 Positive unexpected: sits very good, the thought of using another silicone for the end prototype may not be needed

Negative expected:

Negative unexpected: very hard to get it out of the mold.

#	Time	#parts	#materials	# tools
47	1h	3	plasticine Wood silicone	Drill Nail Glue

How to sew it, the wrong way

When the first time I tried to sew it, I had difficulties with sewing the parts together.

First I sewed the elastic part.

Then I sewed the other two parts

To combine the parts afterward

This photo is taking from a video while making the prototype. It is exactly the moment when I realize this won’t work. By sewing the under part first, I don’t have place to sew the elastic part on is without making the room for the form smaller. So I had to go search for another method for sewing it

So it became clear that I must sew the three parts on one side first and then sew the two sides together

Elements of experience:

Positive expected:

Positive unexpected: it’s easier to sew first the front and back and then combining the two

Negative expected:

Negative unexpected: the mistake of first sewing the three parts on its own

#	Time	#parts	#materials	# tools
46	1h	2	Fabric elastic	Sewing machine scissors

How to make the length of the cords

Measuring the upper and lower leg a maximum, when the leg is bend, and a minimum, when you stand straight, shows that the under leg has an average of 35 cm en the upper 46cm. With these measurements we now cut the cords that will attach the knee protector to the legs. This is shown in the next video.

How to draw on fabric (video test for instructable)

Describing test fabrics

This elastic fabric consists of 6% spandex, if it isn’t elastic enough a fabric with a bigger percentage spandex will be used.

The next few fabrics will be tested for the rougher material:

Cotton: chosen because it absorbs water and for that is good against sweat

Water resistance: when uses outside this fabric may have an advantage

Satin: know to feel real nice on the skin

Polyester viscose: synthetic cotton, a bit rougher than the first cotton presented

Rip test:

For the first selection filter the fabrics where damaged with a sharp object to see how it reacts. By doing this we noticed that the satin and the water resistant fabric aren’t ideal because they rip very fast.

Changing the shape

These following videos show the next steps after prototype 45. After testing prototype 45 it became clear that the bra-closure is the best solution because:

• It is handy to put on
• It stays in place
• Doesn’t create friction
• Can still be used if stretch fabric is stretched out because of the many uses

Now we going to look at changes to the shape and fabric, in the first film you will see with part of the case have with function and why we going to change the shape:

We learn that

• A more elegant shape is created
• A round shape resembles better the knee shape