Editing NBC 2009July13

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==Hack Session 2==
==Hack Session 2==


Hack session 2 was focused on creating the armature for the North Paw kits. Rachel and Eric spent the beginning of it designing and creating prototypes for the mass produced armature, while Skory worked on the belt wiring harness prototype, and David wrote up hack notes for the evening.
Hack session 2 was focused on creating the armature for the North Paw kits. Rachel and Eric spent the beginning of it designing and creating prototypes for the mass produced armature, while Skory worked on the belt wiring harness prototype, and David wrote up hack notes for the evening.
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Eric/Rachel: We tried one with the zipper completely flat, but that didn't give us enough space inside, and made the surface space of the velcro on the outside too small. The design we went with has the zipper folded so that the zipper is on the bend, or the top. Prototyping took an hour and a half.
Eric/Rachel: We tried one with the zipper completely flat, but that didn't give us enough space inside, and made the surface space of the velcro on the outside too small. The design we went with has the zipper folded so that the zipper is on the bend, or the top. Prototyping took an hour and a half.


We then started to work on mass producing the armatures (while David worked on the hack notes still, and then the website, as well as helping to cut the Veltex display loop).
We then started to work on mass producing the armatures (while David worked on the hack notes still, and then the website, as well as helping to cut the Veltex display loop). It took 10 minutes to cut the lining fabric, 15 minutes to cut the fashion fabric, and 20 minutes for the foam inserts. Rachel was sewing zippers to the linging for 25 minutes, worked another 30 for the velcro strips to be sewn to the fashion fabric, 20 minutes to attach the zippers to the fashion fabric, and sewed the lining to the fashion fabric in an hour.
 
Armature process (Rachel did the sewing while Skory, Eric, and David did cutting, trimming, and arranging):
 
# cut 30 pc of display loop, at 11" x 1-1/4" (15 min)
# cut 30 pc of lining, at 11" x 1-1/2" (10 min)
# stitch lining to zipper, zipper upside-down with lining underneath so the feed dogs ease the stretchy lining against the non-stretchy zipper.  i used a little bit of zigzag for the hell of it (25 min)
# cut 30 pc of the hook side of 1" velcro, 3" long (15 min?)
# stitch velcro to one end of the display loop in an X pattern, such that the velcro hooks face down (30 min)
# stitch the display loop/velcro assemblies to the other side of the zippers, with the velcro towards the end of the zipper where the pull is when closed (this end should go on top if the armature must wrap the ankle at all).  zigzag again (20 min)
# serge the non-zipper edge by folding the armature in half down the zipper (20 min)
# serge the non-velcro end of the armature (10 min)
# zigzag the velcro end of the armature (10 min)
# stuff the motor support inside the completed armatures
 
We started at about 10:45 and finished at about 1:30 (numbers don't add up b/c some of the tasks were done in parallel).
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