This project was conceived during my studies at Columbia University's Graduate School of Architecture Planning and Preservation in 2006 (and is the reason why I had access to a Laser Cutter - no longer).
Step 1: Materials
1. E.V.A. Ethylene Vinyl Acetate Foam Sheet, 2mm Thickness, with a variety of colors to choose from (this may come in stock sizes, try to get Approximately 4+ yards material)
2. PVC Clear Vinyl, 12 Gauge or thinner. This should be very flexible, with little rigidity. Approximately 4+ Yards material.
3. Sewing Pins
4. Heavy Duty Nylon Thread
5. Fabric Measuring Tape
6. Tape (optional) - for taping together printed pattern
7. Fabric Shears
8. Printer (or large plotter is easy if accessible) to print pattern
9. Heavy Duty Sewing Machine for Leather/Canvas (if you do not have a heavy duty machine, consult a tailor/upholsterer for assistance)
Computer and Drawing Software (I used AutoCAD, and then Adobe Illustrator to create pattern)
Laser Cutter (to cut patterns)
I purchased the E.V.A foam and PVC Vinyl from Canal Rubber in New York, NY. There are many other rubber/vinyl distrubutors of this kind.