SideshoViD Since I've shared my entire journey of trying to #3dprint a #millinery #hatblock it's only fair I share my setbacks too. I finally steamed and blocked a hat this weekend for the first time and the heat and the pressure were too much for the PLA block. I knew this was a possibility going in. Next steps: try ABS plastic with a higher melting point. If that doesn't work then I'll be looking to print molds and cast blocks out of more resilient materials. The quest continues!!!

SideshoViD Finally, I present to you my finished #3dprinted #millinery #hatblock brim. I had to #3dprint it in 4 pieces and the finished assembly measures about 15"x13". This represents about 72 hours of total #3dprinting time! I just need to glue it up and it's time to block! #dijonmillinery

SideshoViD This is just a fourth of my #millinery #hatblock brim and it takes up almost the entire build plate! Definitely my biggest print to date. 18 hours X 4 to finish it and see how well it assembles! Then, then it will be time to block and see if I need to make any adjustments and start ALL over! #3Dprinting #dijonmillinery

SideshoViD 22 hours later, that's a fine looking #hatblock. Logo and sizing information embedded in the bottom and look, my calculations were correct! I can print this literally ANY size with the touch of a button! Next, it's time to actually block it and see if it makes a halfway decent hat. #3Dprinting #millinery #maker #dijonmillinery

SideshoViD About to hit go on this 24-hour long #3dprint. It's my first #millinery #hatblock since I reworked everything for #3dprinting. Logo and sizing information embedded in the bottom. Can't wait to try to block it! #cura #openscad #3dprinter #dijonmillinery

SideshoViD It's been a challenging weekend on the #3Dprinting front. First extruder clog, first filament tangle, and now first limit switch failure. Sigh. But I did manage to convert my logo to a 3d height map and print a test for branding and sizing my blocks. Hurray for small victories! #dijonmillinery

SideshoViD Things were looking good on my #3dprint when I left for dinner, but came home to this. 😳 There's 10 hours wasted. #3dprinting #3dprintingfail #walkingintospiderwebs #leaveamessageandillcallayouback

SideshoViD Today I #3dprinted a 1/5 scale model of an upturned #millinery #hatblock #brim. To go full scale, I needed to figure out how to #3dprint a large object in pieces and then fit it together with a #dovetail joint. Had a successful scale print on that front too. Progress, progress. #dijonmillinery

SideshoViD For the past 6 years I've been pursuing my #millinery dream of a #3dprinted #hatblock and today I decided to stop testing and go for it. It took 28 hours to print and for sure much innovation will take place to improve the process but it worked!!! I'm over the moon! #hictop #reprap #prusai3 #3dprinting #hatblocks #dijonmillinery

SideshoViD My first attempt at #3dprinting something big! Just an oval the size of my head to test the heated bed and everything. So far so good (minus a few blemishes) #dijonmillinery

SideshoViD One of the benefits of #3dprinting #millinery #hatblocks is the ability to create exact duplicates in any size. Granted these are 1, 1.5, and 2 inches long, but still. Getting there. #dijonmillinery #maker

SideshoViD I could watch this all day. Oh wait, I did. #3dprinted #hatblock #dijonmillinery

SideshoViD Just a couple of #3dprinted scale models of my #millinery #hatblock proof of concept. One step closer to the dream! #dijonmillinery

SideshoViD There really is no substitute for a good lift when blocking. #millinery #dijonmillinery #bowler #hatblock

SideshoViD Nothing left to do on this #hatblock but block it! #millinery #dijonmillinery #bowler

SideshoViD Took a little hiatus during the house building but I'm back at it! Added a little tissue paper this time mostly for aesthetic reasons. #millinery #hatblock #dijonmillinery

SideshoViD Did somebody order a top hat brim #hatblock #millinery #dijonmillinery

SideshoViD And for comparison, the completed #hatblock constructed from layers of 3/16" foam board cut from cross sections of the 3D cad model and assembled then sanded smooth. #millinery #dijonmillinery #fedora

SideshoViD Design files for my latest blocked hat. Manufacturing is improving with each block! Might be time to try more out there designs soon. #dijonmillinery #hatblock #openscad #millinery

SideshoViD Well my hand is now cramped into a gnarled, unusable stump, but at least I have something to show for it. This is harder than I thought. #millinery #hatblock #dijonmillinery #tophat

SideshoViD You can always tell a Dijon! #dijonmillinery #millinery

SideshoViD My new stamp came! Time to start a brand! #dijonmillinery #trodat

SideshoViD I think it's a winner! #millinery #dijonmillinery

SideshoViD Come on, David. You can do this. #millinery #singersewingmachine #singer99 #dijonmillinery

SideshoViD Not looking that great right now but a successful proof of concept. After a little shaving and fitting it'll be a totally custom 6-piece mad hatter puzzle block! #millinery #hatblock #dijonmillinery

SideshoViD Seeing what others from the local #millinery class have done with my #hatblock was unexpectedly exhilarating! #dijonmillinery

SideshoViD Wait, how did I forget I had this in the closet? Grandma's sewing machine still makes a mean stitch!

SideshoViD Off the block, onto the model #dijonmillinery #millinery

SideshoViD Latest custom #hatblock I just finished making blocked nicely today. Wide brimmed #fedora from #dijonmillinery

SideshoViD Add to it until you think it's too much… Then double it! #dijonmillinery #papillon

SideshoViD hatsfordays @cloudxiiidesign

SideshoViD Somebody else blocking my block! It's almost more exciting than doing it myself #millinery

SideshoViD Added some sweet new stickers to my millinery attaché. @katiegazelle

SideshoViD Sizing sprayed, lining tacked in place, just waiting for my leather sweatband to arrive and this one will be done! #millinery #dijonmillinery

SideshoViD May not look like much but it's some of my best sewing ever. Top stitching on the seams of my custom liner from my own six piece pattern (in dijon yellow, of course). #millinery #dijonmillinery

SideshoViD Loving this new Instagram app. Latest hat block blocked without a hitch. New natural fiber ropes worked without pins. So excited to try it on! #millinery #dijonmillinery #hatblock

SideshoViD Checking out the competition #philiptreacy #london #millinery

SideshoViD Have to stop here for today. My cutting hand is cramping up #millinery #hatblock

SideshoViD Visit onestop3Dshop.com for all of your CNC routing, cutting, and scanning needs. Were taking this thing to the next level.

SideshoViD Making sure the fit will be perfect. This one is for me! Another #fedora #hatblock #dijonmillinery

SideshoViD Latest #hatblock today. Decided to hit this one with a coat of paint before the lacquer and final sanding. #millinery #dijonmillinery #cloudxiiidesigns #dcxiii

SideshoViD Finished product. #millinery #maker #babyfedora #dijonmillinery

SideshoViD This is what #millinery means to me these days. Carving a custom #fedora #hatblock

SideshoViD Here we go again. Cross sections for the new #hatblock #millinery #dijonmillinery #maker

SideshoViD First successful photo shoot. Thank you @amc868s for making my model! #millinery #couture #butterflies #flowers #prettyinpink