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This project was a proof-of-concept for the idea of "laminating" or stacking thick felt slices to create a solid form. Refer to my instructable on how to Cut Industrial Felt With a Waterjet for directions on how to make a sliced form with 123D Make and how to use a waterjet machine to cut parts out of 1/2" thick wool felt.

This instructable is a combination of instructions based on the things that I did, and tips based on the following two things that I plan to do differently next time:

  1. Use 123D Make to create alignment guide holes in your parts
  2. Leave the masking paper or frisket on the parts after cutting

I was able to glue the piece together accurately without having done these two things, but they would have made the assembly process easier.

The final product is solid, soft and plush, satisfyingly dense and surprisingly weighty, and looks handsome with or without contents.

Step 1: Materials and Tools

  • Felt pieces (see Cut Industrial Felt with a Waterjet for instructions)
  • White chalk
  • Glue (I used carpenter's wood glue because it dries slowly enough to allow time for repositioning parts and adds strength to the final piece)
  • Foam brushes and a rag or paper towels
  • 2 pieces of scrap wood larger than the largest dimensions of your piece, for clamping
  • Clamps
  • A water glass or other cylindrical water-tight container (2 1/2" diameter by 4 3/8" tall)
<p>Yes, a very cool look. I like that you used 123D for the pattern. It opens up some really intersting shapes.</p>
<p>Very nice. I thought it was some weird lava rock or pumice stone. I'm picturing this with other materials too. Thanks for posting. </p>
<p>very beautyful! it looks like a rock but soft, like organic but clean. Nice!!</p>
<p>For those of us without an industrial waterjet, could we use a knife?</p><p>Also, it would be cool if you included the cutting files...?</p>
<p>Hi Kiteman! I imagine with patience and a pile of fresh Xacto blades, you could cut the parts by hand. If anyone tries it, I'd love to hear how it goes! I just attached the stl, dmx, and eps files to the instructable about <a href="https://www.instructables.com/id/Cut-Industrial-Felt-with-a-Waterjet/" rel="nofollow">making the layout and cutting parts</a>.</p>
<p>:-)</p>
Yes! I love the simplicity behind this piece. Excellent work.
<p>Thank you!</p>
<p>I wonder... Someone could really do some cool work with this! What a wonderful innovation!</p>
<p>Thank you! I've got some plans in the works for incorporating the process into making art pieces and would really love to see where others might take the idea. </p>

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