I felt that I should test my idea to see if it would work, I tried with a small garment, a sock;
I felt I should start with something small as then could get a feel of how many layers of PVA I would need and know what parts would need more PVA to create the garment to stand alone. I thought a sock world be easy, but I found it probably not the best choice. To get the best result from PVA on cloth you have to prevent the mold from moving and using your own foot as the mold made it very hard to keep it at the same angle throughout the whole molding process. I found it took hours to make the PVA strong enough to stand on its own, I had to do it over three days and 100's of coats, the first day was easy as the PVA absorbed fast and dried fast as their was a grater ratio of cloth the PVA, but when taking the sock off it could not stand alone, it was more like an unwashed sock, had some stiffness to it but couldn't keep a 3D form.
Day two to a bit longer to absorb into the cloth as there was already PVA in the cloth, this time I wasted to see what would happen if I put the PVA/boric acid solution into the sock. I found that it made a thicker paste though the sock, it was more difficult to absorb and dry but it made it stronger, I rubbed it into parts of the sock that needed more support like the sides of the sock and the heal, the part that would take most of the weight and needed the most molding. I found this day harder to take the sock off when it had dried as it had taken its from a bit more. it still couldn't stand on its own but you could see a shape forming.
On day three I found it quite hard to get the sock on as the PVA had prevented the sock to have any elasticity it it. I did about 5 more coats of PVA on the sock focusing on the areas which weren't strong enough to stand alone. Day three took the longest to dry as their was less cloth for the PVA to absorb into but I could feel the sock taking form around my foot. The hardest part came when the PVA had dried and that was to take the sock off my foot. As the PVA and molded around my foot an had given the sock a lot of strength and stiffness and also lost a lot of elasticity it was extremely difficult to remove the sock, but with a lot of careful tugging I got it off and it could stand alone.
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