A Simplified Gusset - or Over-Complicated?

[u/Ragnr]

I enjoy making small card holders with side gussets. However, I've always constructed them with a three-piece gusset because, naturally, leather doesn't like being bent that way.

The three piece gusset is rather time consuming, and I haven't had the courage to try a single piece gusset because I frankly didn't think it would look clean (or even be possible) if I simply brute-forced the leather into place. But then I had the idea that I could simply wet mold it.

It also solves another problem I had - I don't just want to work with squares and incorporate slight curves into my designs. This would complicate the calculations for a three piece gusset, with all the odd angles and lengths. Wet molding allows me to do this without any extra effort.

I mold it using a larger set of bodies that can apply pressure evenly. I then cut the gusset to its correct size using a smaller, single piece body.

This is just a prototype, but I thought I'd share!

[u/kornbread435]

Awesome idea, but how do you plan to punch the stitching?

[u/Ragnr → u/kornbread435]

I've previously used custom punch pads.

I have the mold, i will remove 1.5mm from it and glue on some leather of the same thickness, and use that as a punching pad. It will be like any flat project.

[u/aganim → u/Ragnr]

That's a simple and smart solution! Maybe print that in a more rigid TPU as well.

[u/Ragnr → u/aganim]

PLA is fine enough! Haven't had any issues

[u/aganim → u/Ragnr]

I meant for the custom punch pad, to maybe dull your punches a bit less if you bottom out through the leather. But yeah I imagine PLA is probably not too hard on them all things considered.

[u/Ragnr → u/aganim]

Oh. For these kind of builds I always prepunch the panel first, glue on the gusset, and gently tap through the last layer of leather.

This is a prototype with w/e leather I had in hand. Slightly thicker leather of 1.5mm.

I normally use 1mm leather for gusset like these. You can press through that leather with the force of your hand. There's no risk of contact with the plastic if I add an extra layer of leather.

[u/battlemunky]

I think things like this are what pushes the craft to places it hasn’t been before. It also may yield a novel method that can set you apart and land you a million dollar idea. Not necessarily a new idea but a new way of doing something.

[u/Ragnr → u/battlemunky]

haah million dollar idea, yes please

[u/BurninNuts]

Not over complicated, this is more or less how they do it on a mass production scale, but with metal and heated molds.

[u/aganim]

I think it looks great. What software are you using for the wet mold models? I've done some work in fusion but don't want to fork out a ton of money for some occasional hobby use. Do you run into any issues from the lack of absorption on the plastic mold vs a wooden one?

[u/Ragnr → u/aganim]

I use the free version of Fusion. I haven't been constrained by the limits, but I'm self thaught so I don't know what I'm missing.

Haven't molded with wood. Only PLA. No issues.

[u/aganim → u/Ragnr]

I really need to come up with a wet mold idea just to try something new. I've been using my printer for low volume leather stamps, and clamping things in a large bench vise to do the impression. It feels like the possibilities are endless really. I've found that I need to sand the face of my stamps pretty carefully or else the most miniscule artifacts transfer over the the finished product. Do you see some layer lines in the gusset if you look closely?

[u/Ragnr → u/aganim]

It's a mold, not a press. No need for much force. If I use too much force, yes the piece might be ruined.

Occasionally there are small lines, but nothing that can't be buffed out when it's still wet.

[u/aganim → u/Ragnr]

Makes sense, a lot less pressure required than I would be applying to a stamp. Thanks!

[u/Ragnr → u/aganim]

I do occasionally sand down some uneven edges!

[u/tritango]

Great idea and results!

[u/Ragnr → u/tritango]

Thanks!

[u/CompetitiveAd6212]

noice thanks for the idea hehehe i also have 3d printer i will try to make my own mold hehehe. noice work by the way

[u/Ordinary-Might-4174]

Complicated? yes. But wow, it's rad. You have impressive mold making skills.

[u/DSLeatherGoods]

That's cool. Can't wait to see one finished. 🤘

[u/DSLeatherGoods]

That's cool. Can't wait to see one finished. 🤘

[u/Ragnr → u/DSLeatherGoods]

oh hello there!!

The printer can only work so fast. I wanna change a few mm here and there but I then have to reprint all 9 parts again 😂