This has been a slow, iterative process.
I've been "auditioning" paper and cloth to find just the right materials.
Production:Laser-cutting the book board went well, although it does produce a lot of soot on the edges.
I cut strips of flat magnetic sheet (sold as vent covers) to hold large sheets of paper down on the laser bed- a significant improvement from previous trials, when the paper would easily lift up and ruin the cuts:
A curved needle makes it easier to sew a coptic binding:
I developed a process for cutting and assembling the Merriam Cone feature, a stack of concentric circles that need to be glued into one unit. I leave about 1 mm of their outline uncut so I don't lose the tiny pieces through the laser cutter bed. I then stack them on a jig built with two sewing needles to align the first 10 pieces. The final 2 layers cover the holes.
Structure:I am happy with the binding and the shape of the case (hard cover), but many structure-related questions linger. I'm still working out how to...
- embed the magnets in the cover
- secure the sewing to the cover
- fold the cloth around the cover
My goals still look very similar to what I was working on in late 2013. Progress is slow, but I'll keep at it!